Journal of Materials Processing Technology 233 (2016) 107–114

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Journal of Materials Processing Technology

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Fiber laser-MIG hybrid welding of 5 mm 5083 aluminum alloy

Ivan Bunaziv a,∗ , Odd M. Akselsen a,b , Antti Salminen c,d , Anna Unt c
a
The Norwegian University of Science and Technology, Department of Engineering Design and Materials, Richard Birkelands vei 2B, NO-7043 Trondheim,
Norway
b
SINTEF Materials and Chemistry, P.O. Box 4760 Sluppen, NO-7465 Trondheim, Norway
c
Lappeenranta University of Technology, Laboratory of Laser Processing, Tuotantokatu 2, Lappeenranta 53850, Finland
d
Machine Technology Centre Turku Ltd, Lemminkäisenkatu 28, FI-20520 Turku, Finland

a r t i c l e i n f o a b s t r a c t

Article history: Aluminum and its alloys are difficult to weld due to their specific characteristics. New joining methods
Received 6 October 2015 such as high power fiber laser-MIG can provide higher overall productivity compared to the arc welding
Received in revised form 29 January 2016 or laser beam welding. There is huge lack of information on how the specific welding parameters in laser-
Accepted 25 February 2016
arc hybrid welding affect quality of welds such as torch arrangement, distance between heat sources and
Available online 27 February 2016
shielding gas composition while other parameters were kept at constant. Laser-arc hybrid welds with
short separation distance between sources produced severe porosity in one pass 5 mm thick aluminum
Keywords:
alloy sheets welding due to unstable interactions and keyhole frequent collapses. Higher process stability
Hybrid welding
Fiber laser
and lower porosity level can be achieved by applying trailing torch arrangement. Addition of significantly
Porosity more expensive helium to the shielding gas did not provide any benefits in terms of porosity decrease,
Weld quality process stability and mechanical properties of welds overall as was expected with selected welding
Shielding gas parameters.
© 2016 Elsevier B.V. All rights reserved.

1. Introduction where mainly CO2 , Nd:YAG laser beams coupled with TIG, MIG
arc sources has proven its application. Due to inherited filler wire
Aluminum alloys welding can be challenging due to their spe- deposition, MIG process can be more advantageous for welding alu-
cific properties such as high thermal conductivity that requires minum alloys compared to TIG due to possibility to manipulate
higher energy density power sources, high thermal expansion caus- microstructure, better bridgeability, and higher weld metal deposi-
ing higher distortions, high hydrogen and nitrogen solubility at tion capability. Nd:YAG and CO2 have been utilized for many years
high temperatures during fusion welding processes which gen- with TIG sources to join various aluminum alloys. As a result, no
erates porosity, aluminum oxide film Al2 O3 causing incomplete much information is available on fiber laser-MIG hybrid welding.
penetration, and low surface tension or viscosity. Aluminum alloys (Olsen, 2009)
welding with laser beam sources is more difficult due to stronger The first published research on fiber laser-MIG hybrid welding of
evaporization of alloying elements with high power densities that aluminum alloys was in 2004 by Thomy et al. (2005). Subsequently
can cause decreased mechanical properties of welds as stated Seto Allen et al. (2006), Wagner et al. (2006), Yan et al. (2014a,b), Leo
et al. (2001). Since aluminum is highly reflective material for long- et al. (2015), Casalino et al. (2014) applied fiber laser and MIG power
wavelength (10 600 nm) laser beams like CO2 , therefore a high sources with limited success. Casalino et al. (2014) reported coarse
power density threshold is required to form and maintain keyhole porosity, in form of ellipses, issues in welding of 3 mm thick AA5754
during welding process (Olsen, 2009). This can be maintained by due to interrupted dynamics of the keyhole related to low laser-to-
application of short-wavelength (about 1000 nm) laser beams that arc ratio.
require much lower minimum power density threshold to form a According to Leo et al. (2015), where the laser-to-arc power
keyhole. ratio was used as main variable as well, welded 3 mm 5000 series
In the past three decades, aluminum was welded with a suc- aluminum alloy, revealed micro-porosity throughout welds and
cess with proven TIG, MIG, PAW electric arc processes, as well as evaporation of the alloying elements (Mn, Mg) which reduced
with Nd:YAG and CO2 laser beam power sources. Hybrid welding mechanical properties when laser power was increased. The same
problems with evaporization of magnesium and manganese related
to deterioration of mechanical properties of joints were reported
∗ Corresponding author.
by Yan et al. (2014a,b). According to the aforementioned research it
E-mail address: [Link]@[Link] (I. Bunaziv).
can be concluded that no much attention were made to the helium

[Link]
0924-0136/© 2016 Elsevier B.V. All rights reserved.
108 I. Bunaziv et al. / Journal of Materials Processing Technology 233 (2016) 107–114

Table 1
Chemical composition (by weight) of base and filler material.

Material Al% Mn% Cu% Zn% Si% Fe% Mg% Cr%

AA 5083 (Base) balance 0.7 – – – – 4.4 0.15

OK Autrod 5183 (Filler wire) balance 0.8 <0.10 <0.25 0.4 <0.4 4.8 0.15

Table 2
Mechanical properties of base and filler material.

Material Min. Yield point Reh [N/mm2 ] Ultimate tensile strength Rm [N/mm2 ] Break elongation A [%]

AA5083 (Base) 130 280 22

OK Autrod 5183 (Filler wire) 140 300 25

2.2. Welding setup and equipment

High power laser IPG Photonics YLS-10000 ytterbium fiber laser

was used for experiments. The maximum output power of the laser
is 10 kW, the beam was delivered from the equipment to work-
piece via 200 ␮m optical fiber. Fiber laser beam was collimated
with 150 mm lens and had 250 mm focal length. KEMPPI Pro Evo-
lution 5200 was used as MIG source. Constant welding parameters
used in the experiments are listed in Table 3 and varying weld-
ing parameters are presented as the experimental design matrix in
Table 4.
The schematic welding setup used for experiments is shown in
Fig. 1 Fig. 2. The joint type used was I-butt joint without beveling
Fig. 1. The fiber laser-MIG setup of experiment. and welding was done in flat position (PA position according to
EN ISO 6947). No air gap was used in testing and workpieces were
as shield gas composition utilization, arc torch arrangement and tack welded at both sides with MIG source to ensure rigidity and
separation distance between power sources on weld quality. decrease the distortions after welding. Before welding, the AA5083
This paper reveals the coarse porosity formation during fiber plates were mechanically cleaned with stainless steel brush in
laser-MIG hybrid welding of 5 mm AA5083 where aforementioned order to eliminate the aluminum oxide layer.
parameters were studied. Coarse porosity was attributed to sig-
nificant keyhole collapse. Helium as a preferable shielding gas
3. Results and discussion
for aluminum welding had no advantages neither in reduction in
porosity nor in quality of welds overall. The paper provides clarifi-
3.1. The effect of process distance and MIG torch arrangement on
cation how to avoid the coarse porosity in hybrid welding of Al-Mg
welds made in pure argon shielding gas
alloys, effect of shielding gas composition and torch arrangement
on weld quality.
The full penetration was achieved with the leading torch setup
with each process distance (see Fig. 3) as it was expected due to
2. Experimental preheating mechanism of the arc source before laser impingement.
Preheating mechanism increases the temperature of material,
2.1. Materials and consumables simultaneously the absorption for the laser beam increases, and,
consequently, penetration increases as well. However, according
The material for experimental welding was non-heat treat- to Fig. 3 it was not possible to distinguish how much penetration
able, wrought aluminum alloy 5083-O (O designates annealed varies with increasing separation distance between sources due to
state—heat treatment method) of thickness of 5 mm. AA5083 is full penetration in all cases. These results contradicts to Casalino
strengthened by a solid solution of magnesium in the aluminum et al. (2013) who also studied the effect of arc position on quality
matrix as most of 5000 series alloys. Weldability of AA5083 is good of welds where TIG was used as arc source, and it was shown that
compared to other aluminum alloys and not sensitive to hot crack- arc trailing arrangement provided higher penetration depth at the
ing, therefore hot cracking problem is not expected in results. The same speed.
test workpieces were cut with CO2 laser into sizes 250 × 100 mm. Considering the quality, it is noticeable that all welds had sag-
The edge surface quality was rough and heavily oxidized. The chem- ging, probably due to excessive laser power and/or arc power or
ical composition of the AA5083 is presented in Table 1. too low welding speed. The sagging problem can be also related
For AA5083 base metal alloy, the filler wire must have nearly the to the surface tension property, where it is lower than in steels.
same chemical composition (the percentage of alloying elements The problem with low surface tension is that aluminum has a poor
should be higher to partly compensate evaporization of these ele- ability to support the root side of the melt pool. The sagging prob-
ments during welding) and mechanical properties must be a bit lem may be eliminated by implementing the backings strips with
greater in order to avoid problems during and after welding to narrow groove, however it will increase the costs of operation.
compensate the deterioration of mechanical properties after weld- In contrast, with trailing MIG torch setup, full penetration was
ing. Therefore, AA5183 filler wire composition is selected. ESAB OK reached only with minimum separation distance of 1 mm. When
Autrod 5183 is similar to composition of AA5083, the diameter of 3 mm separation process was used, partial (intermittent) pene-
the wire used was 1.2 mm, to provide sufficient filling in thickness tration occurred. Further increase in separation distance by 2 mm
exceeding 3 mm. The chemical composition of filler wire is shown (5 mm in total) leads to incomplete penetration also greater dis-
in Table 1 and mechanical properties are shown in Table 2. tortions of the workpiece. Incomplete penetration was caused due
 I. Bunaziv et al. / Journal of Materials Processing Technology 233 (2016) 107–114 109

Fig. 2. Schematic representation of movement direction of the filler wire molten metal in trailing MIG torch arrangement (a) and in leading MIG torch arrangement (b).

to loss of synergistic effect between two sources since increase of laser zone. The reinforcement height is considerably larger than
of separation distance led to loss of the preheating mechanism. leading torch setup. The reason is the same as decreased penetra-
In addition, with trailing torch setup the flow of molten metal tion effect. With trailing MIG torch arrangement, filler wire molten
differs from leading torch setup in such a way that excessive molten metal spreads more widely due to arc forces since it comes after
metal from filler wire present near keyhole compared to leading laser beam. Moreover, acting forces from arc source behave also
torch setup. This can cause the attenuation of laser beam power differently.
and disturbances of the keyhole. Concerning spattering and other defects which can be examined
The welded bead shape considerably differs when torch direc- visually, it was noticed that trailing torch arrangement provides less
tion was changed (see Fig. 3). Trailing torch direction setup spattering and undercuts compared to leading torch setup which
produces larger width of arc zone and slightly narrower weld width produced relatively much spatter. However, in trailing torch setup

Table 3
Constant parameters.

Parameter Value (Type)

Laser power 2.5 kW

Laser mode CW
Arc mode pulsed arc
Arc current 116 A
Welding speed 1.8 m/min
Filler wire diameter (type) 1.2 mm (solid wire)
Torch angle 60 ± 3◦
Filler wire stick-out 15 ± 2 mm
Filler wire feed rate 6.7 m/min (773 program)
Focal point position −1 mm
Air gap 0 mm
Beam inclination angle 90◦
Collimation length 150 mm
Focal length 300 mm
Sielding gas flow rate 15 l/min

Table 4
Experimental design matrix.

No. Torch direction Separation distance, mm Shielding gas composition

1 Leading 1 Argon 100%

2 Trailing 1 Argon 100%
3 Leading 3 Argon 100%
4 Trailing 3 Argon 100%
5 Leading 5 Argon 100%
6 Trailing 5 Argon 100%
7 Leading 1 Argon–helium mixture (50%/50%)
8 Trailing 1 Argon–helium mixture (50%/50%)
9 Leading 3 Argon–helium mixture (50%/50%)
10 Trailing 3 Argon–helium mixture (50%/50%)
110 I. Bunaziv et al. / Journal of Materials Processing Technology 233 (2016) 107–114

Fig. 3. The effect of separation distance and MIG torch direction on weld appearance and quality in fiber laser-MIG hybrid welding of AA5083 with pure argon shielding gas
(100%).

the undercuts were also observed with 1 mm separation process. spattering level. In contrast, the trailing torch setup almost had no
Occasionally some overlapping was detected in leading torch setup. spattering. However, the bead appearance itself is worse than with
The possible reason of spattering in leading torch setup is that the leading torch setup. Trailing torch setup with 3 mm in separation
droplets of the molten metal from filler wire flow toward the region distance shows a lot of undercutting.
of keyhole after detachment and can block it as illustrated in Fig. 2, Leading torch setup demonstrates (see Fig. 4) full penetration
therefore it is highly possible that spattering is produced. In trail- with 1 mm and 3 mm separation distance and results are quite the
ing torch setup droplets are impinging surface, therefore it is not same as welding in pure argon. When separation distance equal
possible for them to move toward the keyhole (see Fig. 2). It was to 1 mm, the arc pressure in helium is increased, therefore the
noticed that the spattering level did not increase simultaneously reinforcement become more concave.
with increase of separation distance. The probable reason of under-
cuts formed in leading torch arrangement is that the arc is narrower
during hybrid welding.
It can be summarized that trailing torch (or laser leading) 3.3. Tensile test results
setup is more stable than leading torch setup when using pure
argon shielding gas. However, leading torch arrangement provides Transverse tensile strength testing was carried out at ambient
greater penetration and narrower weld shape. temperature (20 ◦ C) according to ISO 4136 and ISO 6892-1. The
results of tensile strength according to variables are presented in
Fig. 5. Since every specimen from experiments was broken in weld
3.2. The effect of process distance and MIG torch direction on seam area, it was possible to examine internal defects and to deter-
welds made in argon-helium mixture shielding gas mine the causes of reduced tensile strength. As can be seen from
Fig. 6 and Fig. 7, coarse porosity is probably the main cause of the
The behavior of penetration is slightly different in argon-helium lower tensile strength of welds compared to base metal, which has
shielding gas compared to pure argon shielding gas. No changes 148 MPa in average.
were noticed concerning sagging, porosity or weld shape from According to Fig. 5, in case of pure argon welding, when separa-
macrographs (see Fig. 3 and Fig. 4). Overall, the visual appearance tion distance at its minimum (1 mm), leading torch setup provides
of welds made with different shielding gases is very similar. better tensile strength since the porosity is lower than with trailing
In case of trailing torch with minimum separation distance torch setup (see Fig. 6). When the separation distance is increasing,
1 mm, the partial (intermitted) penetration was achieved (see trailing torch setup gives better tensile strength and less poros-
Fig. 4). When separation was increased by 2 mm (3 mm in total) ity, at separation distance of 5 mm trailing torch provides porosity
full penetration was reached. These results were unexpected since less than 5% and that quality is accepted by EN 13919-2 standard
in the case of pure argon shielding gas the separation distance is (D level). However, the tensile strength with trailing torch setup
increasing the penetration is decreasing. is decreasing slightly due to incomplete penetration. The poros-
The visual examination of welds revealed fairly the same ten- ity level with leading torch setup according to separation distance
dency of spattering and other defects. Leading torch setup had more behaves uniformly compared to trailing torch setup. The largest
spattering. The spattering level was the same as with pure argon separation distance promotes the highest level of porosity, in con-
shielding gas. Consequently, adding helium does not decrease the trast with trailing torch setup the porosity level was the lowest.
 I. Bunaziv et al. / Journal of Materials Processing Technology 233 (2016) 107–114 111

Fig. 4. The effect of separation distance and MIG torch direction on weld appearance and quality in fiber laser-MIG hybrid welding of AA5083 with argon-helium mixture
shielding gas (50%/50%).

Fig. 5. The effect of process separation distance and MIG torch direction on tensile strength of welds.

The tensile strength response of joints welded in argon-helium porosity with 1 mm separation distance (107 MPa)
mixture shielding gas differs from the joints welded in pure due to high amount of micro-porosity which is not
argon, since increase in separation distance between sources the clearly can be seen from Fig. 7. For the same reason
tensile strength decreases with either leading or trailing MIG torch the weld made in argon shielding gas, having 30%
directions due to porosity as shown in fractured workpieces along porosity level (leading torch, 3 mm separation distance)
welding line (see Fig. 7). The welding made with trailing torch setup demonstrated lower tensile strength.
has better tensile strength in overall. The reason is that the trailing The results of experiments concerning porosity indicates that
torch setup produced less porosity in the joint and probably has helium as shielding gas does not improve the problems with coarse
better stability of the keyhole during welding. The trend of coarse porosity and as consequence does not improve the mechanical
porosity development is the same as with pure argon shielding properties of the welds.
gas. With leading torch setup, the porosity level increases along In general, the tensile strength of welds made in pure argon
the increase of separation distance and in trailing torch setup, shielding gas is slightly higher (by 3.6%) than in argon-helium mix-
porosity levels tend to decrease along the increase of separation ture since hybrid welding in argon seems to be more stable process.
distance. However, the tensile strength has the opposite effect.
Weld with lower level of porosity (15%, 3 mm separation distance)
has lower tensile strength (95 MPa) than the weld having 20%
112 I. Bunaziv et al. / Journal of Materials Processing Technology 233 (2016) 107–114

Fig. 6. The effect of separation distance and MIG torch direction on porosity level in fiber laser-MIG hybrid welding of AA5083 with pure argon shielding gas (100%) of
fractures workpieces parallel to the weld line.

Fig. 7. The effect of separation distance and MIG torch direction on porosity level in fiber laser-MIG hybrid welding of AA5083 with argon-helium mixture shielding gas
(50%/50%) of fractures workpieces parallel to the weld line.

3.4. Coarse porosity The possible reason of coarse porosity is schematically illus-
trated in Fig. 8. The figure demonstrates the possible closures of
It is difficult to understand the reasons of porosity since exper- keyhole during welding due to flow of liquid metal, which after
iments were not photographed with high-speed camera that can some time generates swelling. Moreover, aluminum alloys have
help to identify the true causes of porosity. Instead, it can be low surface tension and swelling created easier than, for exam-
explained theoretically at some level. ple, in welding of steel. The instability of keyhole can be achieved
 I. Bunaziv et al. / Journal of Materials Processing Technology 233 (2016) 107–114 113

Fig. 8. The possible keyhole instability phases that generate coarse porosity in trailing arc (leading laser) setup during hybrid welding, adopted from Xie (1999).

by improper welding speed and laser power. Such instabilities of in upper molten pool of weld, since laser and arc together bring
keyhole can also create other defects such as spattering or under- heat flux to it. That means more heat is accumulating in the arc
fills. Another possible reason of coarse porosity is vaporization of zone, whereas the lower part of weld experiences the heat input
magnesium during the welding process. only from the laser source since laser operates in keyhole regime.
From the study of porosity level in different shielding gases it This phenomenon affects width of the partial melted zone (PMZ)
can be concluded that adding helium to the shielding gas does not as can be seen from Fig. 10. In PMZ always contains high degree
help to reduce porosity. of impurities Moreover, it usually has high tensile residual stresses
The methods to decrease a coarse porosity in welds can be as which leads to hot cracking, high probability of containing hydro-
follows: gen which leads to hydrogen embrittlement. Consequently, it is
preferable to have as shorter width of PMZ as possible.
• Laser beam power should be balanced accurately with welding Fig. 10 illustrates the difference in width of partial melted zone
speed. Lower beam power disturbes the stability of the keyhole (PMZ) in different part weld, namely PMZ between base metal and
and when it collapses, coarse porosity is generated. Higher laser arc zone, PMZ between base metal and laser zone. It is clearly seen
intensity provides high laser-to-arc ratio, therefore de-gassing that PMZ produced by laser beam is negligibly narrow compared
effect cannot be maintained (Ola and Doern 2015). Therefore, to PMZ produced by MIG source. Such a tendency is valid for all
welding speed should be decreased or arc power increased when welded seam produced in experiments.
it is needed without destabilization of the keyhole dynamics due
to higher amount molten filler wire around it (Casalino et al.,
2014).
• Inclinationof beam incidence angle by 30◦ to the surface normal
4. Conclusions
against welding direction can reduce porosity (Katayama et al.,
2006).
In this paper, several important welding parameters were tested
• Introducing the air gap into setup can decrease the porosity, how-
on the quality of welds. Based on the current results, the following
ever the welding speed and therefore filler wire feed rate must
conclusions can be derived:
be increased and other parameters re-considered.

Along with coarse porosity, some hydrogen-induced micro-

porosity was also observed as mentioned previously. One possible • The most often observed weld defect was internal coarse porosity
reason is that preparation for welding was not sufficient. For and at some degree micro-porosity, which significantly decreased
achieving minimum level of micro-porosity, it is generally recom- the tensile strength and overall quality of the welds with selected
mended to prepare the surface by dry machining before welding. welding parameters. Further studies are required on welding
In experiments only mechanical cleaning of aluminum oxide with speed, power balance of the sources to optimize the parameters
stainless steel brush was used, which could be insufficient. Another to achieve higher quality welds.
reason is obtaining hydrogen from filler wire since it has been long • Trailing MIG torch setup provides higher quality weldments than
time exposed to atmosphere and humidity in shielding gas as well. leading MIG due to higher stability of the keyhole, less critical for
the shorter separation distances where droplets of filler wire can
3.5. Microstructural analysis of welds impinge laser beam, and increased the weld pool in the upper
part of weld for de-gassing effect to reduce porosity levels.
Owing to the application of a fusion welding process, the • Spattering levels do not depend on shielding gas composition and
microstructure in the joining zone can be significantly affected by develops mainly with leading MIG torch setup.
heat input during process, as a consequence its mechanical proper- • Additions of helium, as more favorable shielding gas, did not
ties and quality of welds. Microstructures taken from the same weld increase the quality of welds as was expected. The utilization
No.1 (see Fig. 9) indicate that microstructure, in fusion zone (FZ), of more expensive argon-helium mixture shielding gas is not
in arc zone and laser zone is different. Dendritic microstructures reasonable.
can be observed in the arc zone, however in medium quantities. • Dendritic microstructure was observed in arc zone within all
Conversely, in laser zone no dendritic structure can be seen. The welds due to accumulating more heat in upper part of welding
reason is that during hybrid welding most of heat input is released bead.
114 I. Bunaziv et al. / Journal of Materials Processing Technology 233 (2016) 107–114

Fig. 9. The changes in microstructure of the same weld (a) in arc zone and (b) in laser zone.

Fig. 10. The changes in width of PMZ in weld No. 6 (Ar-He 50%/50%): (a) PMZ between fusion zone and base metal (BM) in arc zone; (b) PMZ between fusion zone and base
metal (BM) in laser zone.

Acknowledgements Katayama, S., Naito, Y., Uchiumi, S., Mizutani, M., 2006. Physical phenomena in
porosity prevention mechanism in laser-Arc hybrid welding. Trans. JWRI 35,
13–18.
The authors wish to thank the Research Council of Norway Leo, P., Renna, G., Casalino, G., Olabi, A.G., 2015. Effect of power distribution on the
for funding through the Petromaks 2 Programme, Contract weld quality during hybrid laser welding of an Al-Mg alloy. Opt. Laser Technol.
No.228513/E30. The financial support from ENI, Statoil, Lundin, 73, 118–126.
Ola, O.T., Doern, F.E., 2015. Keyhole-induced porosity in laser-arc hybrid welded
Total, JFE Steel Corporation, Posco, Kobe Steel, SSAB, Bredero Shaw, aluminum. Int. J. Adv. Manuf. Technol. 80 (September (1)), 3–10, 201503/.
Borealis, Trelleborg, Nexans, Aker Solutions, FMC Kongsberg Sub- Olsen, F., 2009. Hybrid laser-arc welding. Woodhead Publishing, pp. 225–245.
sea, Marine Aluminum, Hydro and Sapa are also acknowledged. Seto, N., Katayama, S., Matsunawa, A., 2001. Porosity formation mechanism and
supressions procedure in alser welding of aluminium alloys. Weld. Int. 15 (3),
In addition, the authors would like to express the gratitude the
191–202.
staff of the Laboratory of Laser Materials Processing (Lappeenranta, Thomy C., Kohn H., and Vollertsen F., 2005. Application of high-power fibre lasers
Finland) for carrying out the experimental work in 2012. in laser and laser-MIG hybrid welding. In Paton B. E. and Kovalenko V. S. Proc.
2nd International Conference on Laser Technologies in Welding and Materials
Processing (LTWMP 05), p. 46–48.
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