Laser beam welding of aluminum alloys for automotive applications

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Laser beam welding of aluminum alloys for automotive applications

Martukanitz, R.P. / Smith, D.J. / Armao, F.G. / Baldantoni, A. / Pickering, E.R.

The use of aluminum is rapidly gaining acceptance for structural applications in the automotive industry. While laser beam welding offers many advantages for joining of aluminum alloys, it also possess certain inherent characteristics that differentiates laser beam welding of aluminum alloys from ferrous materials. These characteristics include aluminum's high reflectivity, large differences in vapor pressure between aluminum and many of its alloying constituents, and relatively low surface tension and viscosity in the molten state. This paper addresses process requirements for effectived laser beam welding of aluminum alloys designed primarily for automotive applications and characterization of welded joints commonly used in the automotive industry. Aluminum alloys designed for automotive applications provide substantial specific strength and good crash worthiness while maintaining excellent resistance to corrosion. Laser beam welding also offers many advantages to the automotive industry. When properly integrated into the manufacturing environment laser beam welding provides high productivity, minimal metallurgical degradation to the base material, and low thermal distortion. This is especially important for aluminum alloys where the heat affected zone can dictate the mechanical properties of the weld, and aluminum's higher thermal expansion may result in greater weld distortion when compared to ferrous alloys. However, successful implementation of aluminum alloy technology and laser beam welding within this industry requires process development and joint characterization.