Structural Behavior of an EN AW-6060 Profile during and Immediately after Welding by a Laser-Laser-Hybrid System

Zäh, Michael F.; Roeren, Sven

doi:10.4028/www.scientific.net/AMR.10.133

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In-Process Simulation of Multi-Axis Milling in the Production of Lightweight Structures
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HomeAdvanced Materials ResearchFlexible Manufacture of Lightweight Frame...Structural Behavior of an EN AW-6060 Profile...

Structural Behavior of an EN AW-6060 Profile during and Immediately after Welding by a Laser-Laser-Hybrid System

Abstract:

This paper describes the analysis of thermal and mechanical effects during welding and the following cooling-phase on a welded structure. An off-the-shelf aluminum-profile, as used in other simulation sub-projects of the research center, was chosen as a sample part for the simulation tests. Taking up an important production scenario of lightweight-production, the frontal closing of two profiles is modeled. The development of residual stresses and the distortion is investigated by a thermo-mechanical FE-simulation. The virtually examined process is provided by a hybrid, bifocal laser system consisting of both an Nd:YAG-laser and a high power diode laser (HPDL). For comparison, a single Nd:YAG-process was simulated, too. The theoretically different generation of residual stresses can be verified within the simulation.

Info:

Periodical:

Advanced Materials Research (Volume 10)

Main Theme:

Flexible Manufacture of Lightweight Frame Structures, 2006

Edited by:

Matthias Kleiner, Jürgen Fleischer, Michael Zäh and Marco Schikorra

Pages:

133-142

DOI:

https://doi.org/10.4028/www.scientific.net/AMR.10.133

Citation:

M. F. Zäh and S. Roeren, "Structural Behavior of an EN AW-6060 Profile during and Immediately after Welding by a Laser-Laser-Hybrid System", Advanced Materials Research, Vol. 10, pp. 133-142, 2006

Online since:

February 2006

Authors:

Michael F. Zäh, Sven Roeren

Keywords:

Distortional Behavior, Finite Element (FE) Simulation, Heat Treatment, Joining of Lightweight Structures, Laser Beam Welding, Residual Stress

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References

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Paper TitlePages

Laser Bifocal Hybrid Welding of Aluminum

Authors: Andreas Trautmann, Michael F. Zäh

Abstract: This paper renders research into the fundamentals governing the melt pool dynamics of a hybrid bifocal laser welding system consisting of an Nd:YAG and a high power diode laser (HPDL). The resulting superposition of keyhole by heat conduction mode welding is assayed for extruded aluminum. In particular the diffusion of the surface oxygen layer is considered. By comparing the results attainable by bifocal laser hybrid welding to the constituent laser processes synergetic effects of the laser hybrid can be demonstrated. These are namely the doubling of the welding speed from 2.0 min-1 to 4.0 m min-1, the reduction of the roughness of the weld surface from 60 om to approximately 10 om and an increase in energy transfer efficiency. The experimental investigations verifying these synergies are outlined and discussed.

Bifocal Hybrid Laser Beam Welding and Friction Stir Welding of Aluminium Extrusion Components

Authors: Michael F. Zaeh, Paul Gebhard, Sonja Huber, Markus Ruhstorfer

Abstract: On a global market, new products are subject to rising requirements regarding strength and quality. Simultaneously, the conservation of the environment and natural resources has become a key priority. One approach to these demands is the weight reduction of mechanical components by lightweight construction. The Transregional Collaborative Research Center (TR 10), funded by the German Research Foundation (DFG), is therefore working on the “Integration of forming, cutting and joining for the flexible production of lightweight space structures”. The use of light metals, like aluminium and composite materials is a main part in the TR10 process chain. This paper deals with the challenges of welding of light weight components made out of EN AW-6060. It shows the use and potentials of two innovative joining processes, particularly suited for welding aluminium. Especially developed for the fusion welding of aluminium components, BHLW (Bifocal Hybrid Laser Beam Welding), combines a Nd:YAG and a high power diode laser. The paper will give insight into the findings of the achieved results so far and line out the further proceedings with regard to critical parameters and their effect on the overall laser welding process. For the welding of aluminium composite materials, which play a big role in the TR10 process chain, Friction Stir Welding (FSW) is evaluated. As a solid state joining process, it can be used for the welding of materials that are hardly weldable with fusion welding techniques. In this paper, results of basic experiment for the joining of reinforced aluminium and the resulting process forces are presented.

A Modelling Approach for the Manufacturing Process Chain of Composite Lightweight Structures

Authors: Michael F. Zaeh, Mirko Langhorst

Abstract: In order to support production tasks in the automotive industry, to reduce costs due to a trial and error procedure during process design and plant construction and to secure the accuracy of frame component assemblies, modern simulation methods are applied. In production chains a row of different manufacturing techniques are established. To accompany the number of manufacturing steps with the aid of calculation methods, an interacting of each simulation with the preliminary one is necessary. Such process chains help to determine the structural properties and geometrical accuracy of components and assemblies during manufacturing of composite lightweight structures and ensure their final quality. The basic difficulty of handling aluminium composites with steel reinforcements is the high residual stress level in the reinforcing elements and the adjoining matrix. This stress state can have a significant effect on the desired machining results and the related process itself. Contemplating this reveals the importance of defining a process chain by simulation.

157

Simulative and Experimental Study on Laser Compound Forming of Plate

Authors: Shu Huang, Jian Zhong Zhou, Yi Bin Chen, C.D. Wang, X.D. Yang, Y.C. Dai

Abstract: An appropriate finite element analytical model for laser compound forming (LCF) was established with ABAQUS code, and then some key technical issues in the simulations were studied and solved. Numerical simulation of LCF for V-shape was carried out to study bending deformation, residual stress distribution and micro-profile of AISI-1008 steel plate. After the corresponding experiments of LCF, the bending deformation, forming precision as well as the variation of surface integrities were mainly measured and analyzed. The results indicated that anticipated shape of V-plate could be precisely formed, meanwhile distribution of surface residual stress and surface qualities on plate were under good control.

3857

Study on Machining Distortion of Residual Stress Release

Authors: Jie Chen

Abstract: When machining multi-frame complex components, more than 90% of the materials would be removed, resulting in severe distortion of the parts due to the weakened rigidity and the release of residual stress. This might also lead to stress concentration and damage of the parts. The effect of material removal from residually stressed billet is simulated using FEA software ANSYS, and the causations of distortion is analyzed. To verify the finite element simulation, a high speed milling test on aluminum alloy 7050T7351 is carried out. The results show that the simulation result is consistent with the experimental one. It included that the original residual stress in the blocks of aero-aluminum component is one of key factors to cause machining distortion.

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