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<p>In this paper, the interfacial evolution of copper (Cu) foil-assisted eight-shaped oscillating laser welding for AZ31 magnesium (Mg) and 6061 aluminum (Al) joints was investigated. The critical role of beam oscillation in controlling the laser energy distribution, interfacial evolution and intermetallic compound formation was also revealed. Results show that the fracture of Mg/Al dissimilar joints transition from Al-side (0–30&#xa0;Hz) to Mg-side (above 60&#xa0;Hz) is achieved through oscillation frequency modulation, with the peak fracture load of 784.1 N at 60&#xa0;Hz (90.7% higher than non-oscillated welding). The Mg/Al interface is divided into Mg- and Al-side pools by the Cu foil, where Mg₂Cu and Al₂Cu compounds formed at the interface; thus, the bidirectional metallurgical bonding of Mg/Al is realized by adding Cu foil. Under eight-shaped oscillation, the increased frequency improves laser energy uniformity and molten pool fluidity, leading to Al-side grain fragmentation and refinement. In contrast, Mg-side interface undergoes secondary recrystallization due to periodic heat input from beam oscillation, which promotes the coarsening of grains. The uniform distribution of laser energy creates favorable conditions for Cu metallurgical effects, while the changes in joint performance and fracture modes are closely linked to asymmetric microstructure evolution on both sides of the Mg/Al interface.</p>

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Laser welding of Mg/Al dissimilar joints via Cu interlayer and beam oscillation: Interfacial evolution and fracture migration

  • 期刊论文

  • 发表日期：

    2025年7月30日

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  • Xinyu Wang,
  • Dianwu Zhou,
  • Rui Zhang,
  • Mengying Ye,
  • Zhaoguo He,
  • Congkang Lu,
  • Jiahao Yang,
  • Li Liu

摘要

In this paper, the interfacial evolution of copper (Cu) foil-assisted eight-shaped oscillating laser welding for AZ31 magnesium (Mg) and 6061 aluminum (Al) joints was investigated. The critical role of beam oscillation in controlling the laser energy distribution, interfacial evolution and intermetallic compound formation was also revealed. Results show that the fracture of Mg/Al dissimilar joints transition from Al-side (0–30 Hz) to Mg-side (above 60 Hz) is achieved through oscillation frequency modulation, with the peak fracture load of 784.1 N at 60 Hz (90.7% higher than non-oscillated welding). The Mg/Al interface is divided into Mg- and Al-side pools by the Cu foil, where Mg₂Cu and Al₂Cu compounds formed at the interface; thus, the bidirectional metallurgical bonding of Mg/Al is realized by adding Cu foil. Under eight-shaped oscillation, the increased frequency improves laser energy uniformity and molten pool fluidity, leading to Al-side grain fragmentation and refinement. In contrast, Mg-side interface undergoes secondary recrystallization due to periodic heat input from beam oscillation, which promotes the coarsening of grains. The uniform distribution of laser energy creates favorable conditions for Cu metallurgical effects, while the changes in joint performance and fracture modes are closely linked to asymmetric microstructure evolution on both sides of the Mg/Al interface.