Numerical Simulation of Laser-MIG Hybrid Welding of 7A52 Aluminum Alloy

LIU Ting; ZHAO Xiaoxin; ZHU Jialei; ZHANG Ziyue; WANG Chengyuan; QI Shikong; JIANG Chengyun

doi:10.3969/j.issn.1674-6457.2025.06.016

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (6) : 150-159. DOI: 10.3969/j.issn.1674-6457.2025.06.016

Light Alloy Forming

Numerical Simulation of Laser-MIG Hybrid Welding of 7A52 Aluminum Alloy

LIU Ting, ZHAO Xiaoxin^*, ZHU Jialei, ZHANG Ziyue, WANG Chengyuan, QI Shikong, JIANG Chengyun

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Abstract

The work aims to investigate the coupling mechanism of temperature field change, molten pool evolution and material deformation defects during laser-MIG hybrid welding of 7A52 aluminum alloy, to provide a strong basis for optimizing the hybrid welding process parameters and inhibiting welding defects. With Abaqus finite element analysis software, the numerical simulation of laser-MIG hybrid welding of medium-thick plate 7A52 aluminum alloy was carried out by the combination model of cone heat source and double ellipsoid heat source, and the reliability of the numerical model was verified through welding experiments. The maximum deformation in the actual welding process was about 2 mm, the maximum deformation in the simulation was1.72 mm, the simulated temperature peak value reached 2 050 ℃, the equivalent force peak value reached 301 MPa, and the size and shape of the numerically simulated weld section was basically the same as that of the actual weld section. The selected combined heat source model is suitable for laser-MIG hybrid welding of aluminum alloy, and the best welding process parameters are obtained after experimental optimization. The optimized welding process can effectively inhibit the material deformation defects caused by non-uniform temperature distribution and residual stress concentration during the welding process.

Key words

7A52 aluminum alloy / laser-MIG hybrid welding / heat source model / temperature field / stress field

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LIU Ting, ZHAO Xiaoxin, ZHU Jialei, ZHANG Ziyue, WANG Chengyuan, QI Shikong, JIANG Chengyun. Numerical Simulation of Laser-MIG Hybrid Welding of 7A52 Aluminum Alloy[J]. Journal of Netshape Forming Engineering. 2025, 17(6): 150-159 https://doi.org/10.3969/j.issn.1674-6457.2025.06.016

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Funding

National Natural Science Foundation of China (52205331); Key Project of Beijing Science and Technology Program (KZ202210017023); National Natural Science Foundation of China Key Support Project (U22B20127)