Microstructure and Properties of 6061/3003 Aluminum Alloy Joints Fabricated by Laser Filling Wire Welding

ZHU Jiang; LI Tianqing; REN Xudong

doi:10.3969/j.issn.1674-6457.2026.01.012

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (1) : 125-139. DOI: 10.3969/j.issn.1674-6457.2026.01.012

Advanced Joining Technology

Microstructure and Properties of 6061/3003 Aluminum Alloy Joints Fabricated by Laser Filling Wire Welding

ZHU Jiang^1a, LI Tianqing^1b,2, REN Xudong^1a,2,*

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Abstract

The work aims to optimize the laser welding process of 6061/3003 dissimilar aluminum alloys by controlling laser power and wire feeding speed, to improve the comprehensive performance of the joint and investigate the effect mechanism of process parameters on the microstructure and properties of the joint. Focusing on the laser welding process of 6061/3003 dissimilar aluminum alloys with wire filling, the parameters of laser power and wire feeding speed were changed during welding. The microstructure of the welded joint was observed and analyzed through characterization methods such as scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and volumetric microscopy. The mechanical tensile tests, hardness and corrosion resistance performance tests were carried out with the universal test tensile machine, microhardness tester and electrochemical workstation to explore the effect law of laser process parameters on the microstructure and properties of the welded joint and reveal the effect of variations in process parameters on the weld microstructure and properties. As a result, when the laser power was low, the strengthened phase segregation occurred in the welded joint due to insufficient heat input (0.5-1.2 μm). When the power gradually increased to 1 800 W, the optimized heat input made the needle-like Mg₂-Si phase uniformly distributed (by volume fraction increased to 18%). When the power was high (greater than 2 000 W), grain coarsening and oxide inclusions occurred, leading to decreased joint properties. The mechanical properties and corrosion resistance of the welded joint increase first and then decrease with the increase of laser power and wire feeding speed. When the laser power is 1 800 W and the wire feeding speed is 20 mm/s, the joint property is the best, and the tensile strength, microhardness and elongation reach 146.83 MPa, 76.5HV and 7.36% respectively. The research results enrich the theory of laser wire filling welding of 6061/3003 dissimilar aluminum alloys and can provide certain data support for the actual welding production of 6061/3003 dissimilar aluminum alloys.

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ZHU Jiang, LI Tianqing, REN Xudong. Microstructure and Properties of 6061/3003 Aluminum Alloy Joints Fabricated by Laser Filling Wire Welding[J]. Journal of Netshape Forming Engineering. 2026, 18(1): 125-139 https://doi.org/10.3969/j.issn.1674-6457.2026.01.012

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