冷丝辅助激光-电弧复合焊对铝合金气孔与组织性能的影响

金涛; 刘瑞琳

doi:10.3969/j.issn.1674-6457.2026.06.003

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精密成形工程 ›› 2026, Vol. 18 ›› Issue (6) : 28-36. DOI: 10.3969/j.issn.1674-6457.2026.06.003

新材料及异种材料连接

冷丝辅助激光-电弧复合焊对铝合金气孔与组织性能的影响

金涛^1,*, 刘瑞琳^2,3

作者信息 +

Influence of Cold Wire Assisted Laser-arc Hybrid Welding on Porosity and Microstructure of Aluminum Alloy

JIN Tao^1,*, LIU Ruilin^2,3

Author information +

文章历史 +

摘要

目的针对铸造铝合金激光-电弧复合焊接气孔缺陷突出的问题,探究冷丝辅助工艺对焊缝成形、微观组织、元素分布及力学性能的影响,揭示冷丝调控熔池行为及抑制气孔的机理。方法以ZAlSi20铸造铝合金为研究对象,采用ER4043焊丝进行冷丝辅助激光-电弧复合焊接。在激光功率为1 800 W、电弧电流为170 A、焊接电压为22.1 V条件下,对比无冷丝（0 m/min）与有冷丝辅助（3 m/min）2种工艺。通过X射线探伤统计气孔分布,采用光学显微镜、SEM/EDS分析微观组织与元素分布,测试接头显微硬度与室温拉伸性能。结果冷丝辅助使焊缝正背面成形光亮连续,X射线探伤显示,气孔缺陷得到抑制,气孔由集中分布的大尺寸转变为少量弥散的小尺寸。晶粒由粗大柱状晶转变为细小等轴晶,Si元素分布均匀化,焊缝中心Si含量（质量分数）由9.78%~14.65%的梯度分布变为整体均匀分布,偏析程度降低。焊缝区平均显微硬度由83HV提升至87HV,抗拉强度由220 MPa提高至223 MPa（母材221 MPa）,断裂位置由焊缝转移至母材。结论冷丝辅助通过增强熔池对流,同步细化晶粒并均匀化元素分布,从物理上阻碍气泡合并长大,从而抑制气孔;组织与缺陷的协同优化使接头力学性能提升至母材水平。

Abstract

The work aims to investigate the effect of cold wire assistance on weld formation, microstructure, element distribution, and mechanical properties, and reveal its mechanism in regulating molten pool behavior and suppressing pores, so as to address porosity in laser-arc hybrid welding of cast aluminum alloys. ZAlSi20 alloy was welded with ER4043 wire using the laser-arc hybrid process (laser power: 1 800 W, arc current: 170 A, voltage: 22.1 V). Two conditions (0 m/min vs. 3 m/min wire feed) were compared. Pore distribution was examined by X-ray, microstructure and element distribution by OM and SEM/EDS, and mechanical properties by microhardness and tensile tests. Cold wire assistance resulted in bright and continuous weld appearances on both the front and back sides. X-ray inspection showed that porosity defects were suppressed, with pores transforming from large, concentrated ones into a small number of finely dispersed small-sized pores. Microstructure evolved from coarse columnar to fine equiaxed grains. Si distribution became uniform, eliminating the original gradient (9.78wt%-14.65wt%). Weld microhardness increased from 83HV to 87HV, tensile strength from 220 MPa to 223 MPa (base metal: 221 MPa), and fracture location shifted from weld to base metal. In conclusion, cold wire assistance enhances molten pool convection, refining grains and homogenizing element distribution, which physically suppresses bubble coalescence and reduces porosity. The collaborative optimization of structure and defects improves the mechanical properties of the joint to the level of the base metal.

导出引用

金涛, 刘瑞琳. 冷丝辅助激光-电弧复合焊对铝合金气孔与组织性能的影响[J]. 精密成形工程. 2026, 18(6): 28-36 https://doi.org/10.3969/j.issn.1674-6457.2026.06.003

JIN Tao, LIU Ruilin. Influence of Cold Wire Assisted Laser-arc Hybrid Welding on Porosity and Microstructure of Aluminum Alloy[J]. Journal of Netshape Forming Engineering. 2026, 18(6): 28-36 https://doi.org/10.3969/j.issn.1674-6457.2026.06.003

中图分类号： TG401

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