Effect of process parameters on pulsed laser welding of AA5083 alloy using response surface methodology and pulse shape variation

Aluminium alloys exhibit eco-friendly aspects related to global environmental issues, such as almost unlimited recyclability. Nevertheless, some intrinsic characteristics are challenges to explore all their benefits. In the welding process, the high thermal conductivity and low melt point require high control of heat input. Alternatively, the pulsed laser mode provides a sharp beam focus with precise control enabling regulating the energy delivered. In this sense, this present work analysed the effect of pulsed laser welding parameters on 3-mm-thick AA5083 aluminium alloy sheets. Trials targeted to develop sound welds with minimum defect and high penetration depth adopting statistical methods. The optimum parameter arrangement was achieved by varying peak power, spot diameter, and pulse duration. Finally, the best parameter combination was applied using different pulse shapes to mitigate crack formation and pores. As a result, the pulse shape with step-down at the end of each pulse generated crack-free spot welds.

Automated summary

Aluminium alloys have eco-friendly characteristics, such as almost unlimited recyclability, that are related to global environmental issues. However, the high thermal conductivity and low melt point of these alloys pose challenges in exploring their full benefits. This study used pulsed laser welding to analyze the effect of welding parameters on AA5083 aluminium alloy sheets. Statistical methods were employed to develop sound welds with minimal defects and high penetration depth. Variation in peak power, spot diameter, and pulse duration resulted in an optimal parameter arrangement, and the use of different pulse shapes helped mitigate crack formation and pores, ultimately achieving crack-free spot welds.