Overlap laser welding of 5052-H36 aluminum alloy: experimental investigation of process parameters and mechanical designs

Abstract In this study, the laser welding process is used to join 1.6-mm-thick AA5052-H36 sheets in an overlap joint configuration. Both pulse and oscillation beam were investigated for first pass. Oscillation continuous-wave mode show more stable sound weld with no porosity defects compare wave (PW) mode. The adopted power, speed, frequency, defocus are 8 kW, 6.5 m/min, 150 Hz, + mm, respectively. obtained stitch welds free (blowholes, micro-cracks, or porosities). A circular ramp-up/ramp-down PW a second surface re-melting (LSR) corresponding 5 2.5 500 15 Shear tests then performed evaluate mechanical properties of single lap joints (SLJ) different shapes, 2 gap tolerances (0 0.5 mm), as well with/without LSR best tests’ reproducibility highest dissipated energies (~ 42% when compared perpendicular direction) direction corresponds loading direction. pass provides aesthetic higher shear resistance 1% 3%) due decrease underfill undercut imperfections weld. part-to-part leads 20%) owing main reasons: larger surfaces at interface hardness fusion zone. These findings great value including technology automotive transportation industries. Graphic abstract