US20050028897A1 - Process for avoiding cracking in welding - Google Patents

Process for avoiding cracking in welding Download PDF

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Publication number
US20050028897A1
US20050028897A1 US10/492,262 US49226204A US2005028897A1 US 20050028897 A1 US20050028897 A1 US 20050028897A1 US 49226204 A US49226204 A US 49226204A US 2005028897 A1 US2005028897 A1 US 2005028897A1
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Prior art keywords
heat source
parts
welding
melt pool
sources
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Abandoned
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US10/492,262
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Wilfried Kurz
Jean-Daniel Wagniere
Michel Rappaz
Milton Fernandes De Lima
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Ecole Polytechnique Federale de Lausanne EPFL
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Individual
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Assigned to ECOLE POLYTECHNIQUE FEDERALE DE LAUSANNE reassignment ECOLE POLYTECHNIQUE FEDERALE DE LAUSANNE ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FERNANDES DE LIMA, MILTON, RAPPAZ, MICHEL, WAGNIERE, JEAN-DANIEL, KURZ, WILFRIED
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/0604—Shaping the laser beam, e.g. by masks or multi-focusing by a combination of beams
    • B23K26/0608—Shaping the laser beam, e.g. by masks or multi-focusing by a combination of beams in the same heat affected zone [HAZ]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/0604—Shaping the laser beam, e.g. by masks or multi-focusing by a combination of beams

Definitions

  • the invention is related to a welding, repair welding or cladding process of metallic alloys according to the preamble of the independent claim 1 . It is further related to the use of the welding, repair welding or cladding process and to work pieces welded or clad with the process. Its main aim is the prevention of hot-crack formation during the process.
  • Riveting, TIG and MIG welding are traditional processes in the manufacturing industry although they present some important weaknesses. Rivets form weak joints and are especially vulnerable to stress corrosion cracking. TIG and MIG produce large heat-affected zones (HAZ), where alloys experience additional solution treatments and averaging, thus leading to a degradation of material properties and a reduction in lifetime.
  • Laser welding is a particularly interesting approach for the construction of metallic structures. New developments in laser technology, such as fiber-optic delivery of YAG beam and high-power diode lasers, have increased and will increase in the future their use in high volume production.
  • aluminium alloys are weldable provided the solidification interval is relatively small.
  • Some classes of aluminium alloys such as 2xxx (Al—Cu), 5xxx (Al—Mg), 6xxx (Al—Mg—Si) and 7xxx (Al—Zn— . . . ) often crack during autogenous welding.
  • Industrial experience has shown that hot cracking can be avoided by the addition of a eutectic-forming alloy, such as a Al—Si wire, to the weld. This methodology is widely applied to the construction of aluminium parts, even if the mechanical properties of the weld are not as good as those of the base material.
  • hot cracking is used to denote brittleness at temperatures above the solidification end (often the eutectic temperature) which is due to the presence of residual liquid films in-between the dendritic grains of the solidifying alloy.
  • Materials in which such cracking occurs invariably possess a large solidification interval, since pure metals and eutectic alloys are not susceptible to hot cracking.
  • the formation of primary dendrites begins close to liquidus temperature, and during subsequent cooling these dendrites grow at the expense of the liquid.
  • the alloys have essentially the properties of a liquid.
  • the alloy is therefore susceptible to cracking while it is in the brittle temperature range (BTR), i.e. at a temperature corresponding approximately to the last 10% of liquid.
  • BTR brittle temperature range
  • the invention is related to an improved welding process that overcomes the problem of cracking and in particular of hot cracking.
  • the process according to the invention is characterized by the features of the characterizing part of the independent claim 1 .
  • the depending claims are related to favorable improvements of the invention.
  • the process provides for crack free welding of work pieces and in particular metal sheets.
  • FIG. 1 a show a schematic, perspective view of two work pieces that are welded according to the invention
  • FIG. 1 b is a schematic side view of the welding area and a solidification profile of the different solid fractions during the solidification of a dendritic network of the welded area of a work piece.
  • FIG. 1 c is a schematic representation of dendritic solidification with associated solid fraction as a function of distance and phase diagram.
  • FIG. 2 a shows a schematic side view of the welding setup
  • FIG. 2 b is a schematic side view of the laser setup and one possible configuration of a gas supply and gas suction nozzles of the welding setup.
  • FIGS. 3 a and 3 b show the pictures of two sheets welded with a CO 2 laser according to a prior art method ( FIG. 4 a ) and two sheets welded with the process according to the invention ( FIG. 4 b );
  • FIG. 4 is an example of a temperature-time curve measured by a thermocouple placed close to the weld trace for welding process according to the prior art FIG. 4 a and the temperature-time curve of the welding process according to the present invention FIG. 4 b;
  • FIG. 5 is the picture of a specimen welded in the lower part with a conventional welding process and in the upper part with the process according to the invention, showing crack healing over the transient zone for an overlapped joint.
  • hot cracks can be distinguished from other cracks formed at distinctly lower temperature by detached grains and crack surfaces decorated by dendrites.
  • the residual liquid remains on both fractured surfaces, which sometimes shows a eutectic layer.
  • a few spikes resulting from the opening of inter-granular grain boundaries are also characteristic of hot-cracked surfaces. In most cases, these effects can only be perceived with a scanning electron microscope.
  • FIG. 1 a and FIG. 1 b A possible arrangement for practicing welding process is shown schematically in FIG. 1 a and FIG. 1 b , as well as in FIG. 2 a and FIG. 2 b .
  • the two metal sheets 11 and 12 are arranged next to each other, thereby forming a gap 10
  • the metal sheets 11 and 12 are moved in the direction of arrow A.
  • the laser beam 15 of a CO 2 laser is directed to the surface are of the two sheets 11 and 12 , and bridging the gap 10 .
  • the laser beam 15 is meting the two sheets 11 and 12 and forms a melt pool 14 .
  • a second laser beam 13 of a YAG laser is directed to the mushy zone 144 region of the melt pool 14 .
  • the laser beam 13 is following the laser beam 15 . It would of course also be possible that the laser beams 15 and 13 are moved in stead of the two sheets 11 and 12 . In this case the laser beams 15 and 13 would be moved in the direction opposite to the direction indicated by arrow A. In another arrangement both, the sheets 11 and 12 as well as the laser beams 11 and 12 can be moved relative to one another. As can be seen there is no overlap of the spots of the energy sources 15 and 13 on the sheets.
  • FIG. 2 illustrates in more detail and schematically dendritic solidification with associated solid fraction as a function of distance and the phase diagram.
  • the mushy zone 144 is also named the dendritic solidification region or zone, where the f s the solid fraction is 0 ⁇ f s ⁇ 1. This means that in the mushy zone/dendritic solidification region/zone there is dendritic solid material, but that there is still liquid material in this zone. 0 ⁇ x % ⁇ 100% of the material is still in the liquid phase.
  • the process is performed under gas protection.
  • the gas supply nozzle G supplies the inert gas and the gas suction nozzle S sucks the gas, so that the melt pool 14 is well protected by the gas flowing from nozzle G to nozzle S.
  • the sheets 11 and 12 of FIG. 2 b can be seen, that the sheets 11 and 12 are arranged overlapping each other in the area that is welded.
  • the process may also be performed with lasers beams of the same type.
  • the laser beams may come from two separate laser sources or the laser beams laser beams.
  • the conditions for avoiding cracks can be analyzed.
  • the transverse stress distribution near the melt pool along the weld centerline consists of three typical regimes. Firstly, compression forces are observed ahead of the melt pool due to heating and thermal expansion of the solid. Secondly, liquid formation with a free surface accommodates the stresses. Thirdly, tensile forces build up as soon as the mushy zone begins to behave as a continuous solid. These tensile forces, which can result in final deformation of the welded part and/or in residual stresses, are often responsible for hot cracks.
  • the control of process conditions could reduce stresses behind the melt pool.
  • the clamping distance directly influences stresses.
  • a small clamping distance decreases tensile stresses because of the expansion of the sheet. If the thermal conductivity and interaction time are sufficiently large this effect leads to compression of the mushy zone and prevents cracking.
  • the sheets are overlapped this effect leads to sliding, thereby producing cracks in the interface between the sheets. Usually this occurs after complete solidification thus producing cold cracks. Reducing welding heat input and speed also decreases the transverse stresses, increasing the resistance against cracking.
  • Rappaz et al. assessed the influence of stain rate on the HCS (Hot Cracking Susceptibility); their model is based on the maximum tensile/shear strain rate which can be supported by the mushy zone before cracks appear.
  • the stain rate can be decreased if the cooling rate during solidification is reduced, i.e. if the solidification speed and/or the thermal gradient are reduced.
  • a eutectic-forming alloy to the weld is recommended as it increases the permeability of the mushy zone in the regions where shrinkage and stresses occur.
  • a 4043 Al—Si alloy wire to the 6061 alloy weld reduces the hot cracking susceptibility.
  • both the yield and ultimate strengths are reduced by 50%.
  • the weld microstructure also plays a role in hot cracking. It is essentially controlled by the growth speed V and the thermal gradient G at the solidification front, but also by the inoculation conditions.
  • V growth speed
  • G thermal gradient
  • Two mechanisms can decrease the HCS of this centreline boundary: formation of equiaxed grains and a variation in grain orientation.
  • the laser welding process according to the invention in principle includes a precisely controlled cooling cycle and associated stress build-up evolution. This is achieved by the combination of two or more heat sources such as laser beams ( FIG. 1 ). Positioning the laser source over the sensitive region of the melt pool which is the mushy zone, this results in
  • FIG. 2 shows a schematic representation of the welding setup, showing in FIG. 2 a the fixture system and the sheets and in FIG. 2 b the setup with the CO 2 laser beam and the YAG laser beam, together with the gas supply nozzle G and the gas suction nozzle S.
  • the alloy was delivered in a T6 condition, after solution heat-treatment at 540° C. for a short time, air cooling, and a precipitation (aging) treatment at 205° C. for several hours.
  • the sample dimensions were 100 ⁇ 50 ⁇ 1 mm sheets which were welded with an overlap of 8 mm FIG.
  • the laser workstation consisted of two lasers, one CO 2 and one YAG laser, a CNC controlled table (with linear scanning velocities up to 0.5 m/s) and a gas protection system, FIG. 2 b .
  • the 1.7 kW CW—CO 2 laser produced a minimum focal spot of about 0.26 mm diameter with an off-axis parabolic mirror with 152 mm focal length.
  • the 1.2 kW pulsed mode YAG laser produced a 0.6 mm focal spot given by the diameter of the optical fibre.
  • the mean spot size of the second laser was defocused giving an elliptical 1.2 ⁇ 1.5 mm spot with the longer axis aligned in the direction of the laser movement
  • Inert gas was applied through a nozzle and evacuated through a suction system to direct the gas stream and protect the optics. This suction system also moved the plasma plume away from the second laser spot allowing a free interaction of the second laser beam with the sample surface without plasma formation. Pure helium was found to be better than argon, or a mixture of Ar/He, since the plasma was smoother and less metal particles were ejected.
  • the gas flux was set at an intermediate value of 5 l/min (too high fluxes disturbed the liquid bath and too low fluxes did not protect against oxidation). The best gas injection angle was found to be about 30° from the sample surface plane ( FIG. 2 b ).
  • the surface cleanness is important for a high quality weld. Dirty and oxidized surfaces produce bubbles in the welds. Washing with water and ethanol followed by ultrasonic cleaning gave sufficient surface cleanness to produce good welds. Laser-cleaning prior to welding was also tried. A Q-Switched YAG laser was used to clean some samples as an alternative to traditional cleaning with excellent results.
  • the welding speed was fixed at 60 mm/s with 1700 W CO 2 power. In other arrangements welding speeds of 100 mm/s and more are possible.
  • the average YAG laser power was fixed at 1200 W, and the following range of process parameters were investigated:
  • the dual beam method produces an enlarged liquid bath.
  • the result of the dual beam method is shown in FIG. 3 b , where there is no crack at all. Bubbles in the weld disappeared when the dual laser method was applied as length of the liquid bath (L) was increased, thus increasing the time for bubbles to rise to the surface.
  • FIG. 4 shows the temperature-time curve for a welding process with a single laser beam (curve a) and the temperature-time curve for a welding process with a dual laser beam (curve b) with a welding process according to the invention.
  • FIG. 4 shows the thermal history (a) and the cooling rate (b) during welding for single laser beam (curve a) and dual laser beam (curve b) experiments.
  • the peak temperature was unaffected by the use of the second source, but the cooling rate in the critical location was substantially reduced, from 2600° C./s to 1500° C./s (curve b).
  • FT free feeding time
  • CT constrained feeding time
  • the feeding time is four times greater in the welding process according to the invention than in the single source case, and the HCS according to Clyne is now 0.12 in comparison with 0.5 for the single source process. Therefore, the welding process according to the invention reduces cracking by extending the time where the liquid can feed the growing solid.
  • the thermal gradient can be estimated with a semi-empirical thermal model.
  • the results at the centerline show that the thermal gradient at the beginning of mushy zone was reduced from 400 K/mm to 175 K/mm This decrease has consequences on the microstructure, leading to equiaxed dendrites near the centerline.
  • the difference between the laser welding process according to the present invention, and conventional welding processes is the use of two or more locally and intensity wise well-controlled heat sources. Although this can be performed by any combination of available heat sources, as far as they are localized enough, it appears that laser technology has a major advantage over others methods because of the very precise control of spot size, position and heat input, essential to the effectiveness of the present technique.
  • the effect of the dual laser system on strain rate can be discussed in the following way: under the assumption of a fully constrained weld, the mechanical stain rate is equal to the opposite of the thermally induced strain rate. This later value is proportional to the cooling rate, which can be controlled by the present welding method. Taking the values shown in FIG. 4 , the strain rate at the critical location is decreased to nearly half of the value for conventional CO 2 welding by the use of the second laser source. The important point is that this second laser acts directly on the final part of the mushy zone, thus reducing the cooling rate most effectively, where it is needed.
  • the new welding process avoids cracking in welding, in repair welding or in cladding of parts of metallic alloys which are sensitive to hot cracking.
  • the process is using a first heat source 15 , directed to the parts 11 , 12 of the metallic alloy forming a melt pool 14 on the parts 11 , 12 of metal or metallic alloy.
  • the heat source 15 and the parts 11 , 12 are moved relative to each other.
  • the process is characterized in that there is one 13 or more additional heat sources directed to the parts 11 , 12 of metal or metallic alloy and following the first heat source 15 in a distance and with substantially the same speed and in the same direction as the first heat source 15 .
  • the additional heat source 13 or heat sources are directed to the solidification region (mushy zone) 144 of the melt pool 14 generated by the first heat source 15 .
  • the power of the additional heat source 13 is set such as to reduce the local cooling rate of the solidification region 144 of the melt pool 14 , or to even shortly reheat this region without substantial remelting or with no remelting it at all and thereby reducing the tensile stresses or even inducing compressive stresses. During this process a central equiaxed zone might also be enhanced. By this new process the formation of hot cracks is avoided.

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  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Engineering & Computer Science (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Laser Beam Processing (AREA)
US10/492,262 2001-10-09 2002-10-08 Process for avoiding cracking in welding Abandoned US20050028897A1 (en)

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EP01810986 2001-10-09
EP01810986.8 2001-10-09
PCT/EP2002/011270 WO2003031108A1 (fr) 2001-10-09 2002-10-08 Procede permettant d'eviter la fissuration pendant le soudage

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