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

JIN Tao; LIU Ruilin

doi:10.3969/j.issn.1674-6457.2026.06.003

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (6) : 28-36. DOI: 10.3969/j.issn.1674-6457.2026.06.003

Joining of New Materials and Dissimilar Materials

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

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

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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.

Key words

cast aluminum alloy / laser-arc hybrid welding / cold wire assistance / porosity suppression / mechanical properties

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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

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Funding

2025 Open Project of the Key Laboratory of Manufacturing and Application of Intelligent Well Control for Oil and Gas Production and Transportation of Luzhou (2025LZOGB-04)