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<p>Al-Mg-Si-Cu alloy has become a key lightweight material in advanced manufacturing due to its excellent strength-to-weight ratio and age-hardening capacity. However, a key issue with the laser-arc hybrid welding of this alloy is its high-porosity rate, which significantly reduces the mechanical properties of the welded joint. Therefore, this study proposes a synergistic optimization strategy combining Si-enriched filler wire and beam oscillation parameters. Using ER4047 welding wire (11.0&#xa0;wt.% Si) reduces the dendritic growth rate by &gt; 15% at the molten pool peripheries, extending the escape time of hydrogen bubbles and decreasing the porosity from 2.8% (with ER4043 wire) to 1.0%. Further optimization of beam oscillation parameters enhances keyhole stability and melt pool convection, achieving an ultralow porosity of 0.3%. The oscillation-induced convection also promoted heterogeneous nucleation, expanding the equiaxed grain zone from 0.6 to 1.6&#xa0;mm. This dual optimization resulted in welded joints (O-ER4047) with a tensile strength of 255.3&#xa0;MPa and an elongation of 4.5%, representing improvements of 5.6% and 68.0%, respectively, over joints made with conventional ER4047 wire. The corresponding strength-plasticity product reached 1160&#xa0;MPa%, a 190% enhancement, attributed to the combined effects of low porosity and a refined equiaxed grain region.</p>

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Porosity Suppression Mechanism and Mechanical Property Enhancement in Laser-Arc Welded Al-Mg-Si-Cu (6D10) Alloys Using Si-Enriched Filler Wire

  • 期刊论文

  • 发表日期：

    2026年3月2日

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  • Pengfei Pei,
  • Xiaming Chen,
  • Shuncun Luo,
  • Nagaumi Hiromi

摘要

Al-Mg-Si-Cu alloy has become a key lightweight material in advanced manufacturing due to its excellent strength-to-weight ratio and age-hardening capacity. However, a key issue with the laser-arc hybrid welding of this alloy is its high-porosity rate, which significantly reduces the mechanical properties of the welded joint. Therefore, this study proposes a synergistic optimization strategy combining Si-enriched filler wire and beam oscillation parameters. Using ER4047 welding wire (11.0 wt.% Si) reduces the dendritic growth rate by > 15% at the molten pool peripheries, extending the escape time of hydrogen bubbles and decreasing the porosity from 2.8% (with ER4043 wire) to 1.0%. Further optimization of beam oscillation parameters enhances keyhole stability and melt pool convection, achieving an ultralow porosity of 0.3%. The oscillation-induced convection also promoted heterogeneous nucleation, expanding the equiaxed grain zone from 0.6 to 1.6 mm. This dual optimization resulted in welded joints (O-ER4047) with a tensile strength of 255.3 MPa and an elongation of 4.5%, representing improvements of 5.6% and 68.0%, respectively, over joints made with conventional ER4047 wire. The corresponding strength-plasticity product reached 1160 MPa%, a 190% enhancement, attributed to the combined effects of low porosity and a refined equiaxed grain region.