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<p>This study employs laser-cold metal transfer (CMT) hybrid welding technology (with laser power accounting for 89.94%) to weld aluminum alloy 6082-T6 (AA6082-T6), and systematically investigates the effect of different butt gaps (0–0.15&#xa0;mm) on weld forming quality, microstructure, and mechanical properties. Results show that 0.15&#xa0;mm gap achieves optimal forming quality, with a porosity of only 1.64% (satisfying ISO 13919–2 Grade B). This is because although the melt pool mode at this gap is a keyhole mode, its Rayleigh jet instability is the weakest. Microstructure that as the butt gap increases to 0.15&#xa0;mm, the partially melted zone (PMZ) decreases to 39.84&#xa0;μm, the secondary dendrite arm spacing (SDAS) decreases to 5.01&#xa0;μm, and partially equiaxed crystals form. These results are related to the increase in the cooling rate (CR). Additionally, scanning electron microscope (SEM) analysis shows that the Si element segregation and oxide inclusion phenomena are weakest under the 0.15&#xa0;mm gap, which is consistent with the decreasing trend of SDAS. Mechanical properties show that the weld with a 0.15&#xa0;mm butt gap has the best performance. Its average microhardness is 78.72 HV, ultimate tensile strength (UTS) is 213.83&#xa0;MPa, elongation (EL) is 6.32%. Compared with the 0&#xa0;mm gap weld, its UTS and EL increase by about 8% and 85%, respectively. And only the 0.15&#xa0;mm gap weld achieves a UTS approaching 70% of the base material’s UTS. Fractographic analysis shows brittle-ductile fracture in the 0.15&#xa0;mm gap weld, while other gap sizes show brittle fracture.</p>

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Effect of different butt gaps on laser-CMT hybrid welding of aluminum alloy 6082-T6: forming quality, microstructure and mechanical properties

  • 期刊论文

  • 发表日期：

    2025年12月3日

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  • Haoquan Zhang,
  • Qingmian Ni,
  • Xiaoquan Yu,
  • Siwei Du,
  • Yulei Feng,
  • Shuquan Zhang

摘要

This study employs laser-cold metal transfer (CMT) hybrid welding technology (with laser power accounting for 89.94%) to weld aluminum alloy 6082-T6 (AA6082-T6), and systematically investigates the effect of different butt gaps (0–0.15 mm) on weld forming quality, microstructure, and mechanical properties. Results show that 0.15 mm gap achieves optimal forming quality, with a porosity of only 1.64% (satisfying ISO 13919–2 Grade B). This is because although the melt pool mode at this gap is a keyhole mode, its Rayleigh jet instability is the weakest. Microstructure that as the butt gap increases to 0.15 mm, the partially melted zone (PMZ) decreases to 39.84 μm, the secondary dendrite arm spacing (SDAS) decreases to 5.01 μm, and partially equiaxed crystals form. These results are related to the increase in the cooling rate (CR). Additionally, scanning electron microscope (SEM) analysis shows that the Si element segregation and oxide inclusion phenomena are weakest under the 0.15 mm gap, which is consistent with the decreasing trend of SDAS. Mechanical properties show that the weld with a 0.15 mm butt gap has the best performance. Its average microhardness is 78.72 HV, ultimate tensile strength (UTS) is 213.83 MPa, elongation (EL) is 6.32%. Compared with the 0 mm gap weld, its UTS and EL increase by about 8% and 85%, respectively. And only the 0.15 mm gap weld achieves a UTS approaching 70% of the base material’s UTS. Fractographic analysis shows brittle-ductile fracture in the 0.15 mm gap weld, while other gap sizes show brittle fracture.