Research and Progress in Laser Welding of Wrought Aluminum Alloys. II. Metallurgical Microstructures, Defects, and Mechanical Properties

TLDR

Laser welding is essential for aluminum alloys in automotive, aerospace, and other industries, with CO₂ and Nd:YAG lasers used—especially Nd:YAG keyhole mode for 5000/6000 series—and prior work has examined processing parameters affecting quality. This review critically examines laser welding of wrought aluminum alloys to understand how processes influence joint quality and to establish a scientific foundation for reliable production. The review discusses the formation mechanisms of defects—porosity, cracking, oxide inclusions, and alloying element loss—in laser‑welded aluminum alloys, their influencing factors and remedies, and evaluates key mechanical properties including hardness, tensile, fatigue strength, and formability. The review evaluates key mechanical properties—hardness, tensile and fatigue strength, and formability—of laser‑welded aluminum alloys.

Abstract

With the wide application of aluminum alloys in automotive, aerospace, and other industries, laser welding has become a critical joining technique for aluminum alloys. In this review, the research and progress in laser welding of wrought aluminum alloys are critically discussed from different perspectives. The primary objective of the review is to understand the influence of welding processes on joint quality and to build up the science base of laser welding for the reliable production of aluminum alloy joints. Two main types of industrial lasers, carbon dioxide (CO2), and neodymium-doped yttrium aluminum garnet (Nd:YAG), are currently applied but special attention is paid to Nd:YAG laser welding of 5000 and 6000 series alloys in the keyhole (deep penetration) mode. In the preceding article of this review (part I), the laser welding processing parameters, including the laser-, process-, and material-related variables and their effects on welding quality, have been examined. In this part of the review, the metallurgical microstructures and main defects encountered in laser welding of aluminum alloys such as porosity, cracking, oxide inclusions, and loss of alloying elements are discussed from the point of view of mechanism of their formation, main influencing factors, and remedy measures. The main mechanical properties such as hardness, tensile and fatigue strength, and formability are also evaluated.