Controlling solidification cracks in laser beam welding of AA6005 using Al2O3 and TiC nanoparticles dispersed in a Cu coating
Laser beam welding is a critical joining method for wrought 6xxx series aluminium (Al) alloys; however, its broader adoption is hindered by the susceptibility to solidification cracking, which undermines weld integrity and restricts the production of high-quality joints. To mitigate cracking suscept...
Saved in:
| Main Authors: | , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2025-12-01
|
| Series: | Journal of Advanced Joining Processes |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2666330925000652 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1849228337019355136 |
|---|---|
| author | M.H. Khan S. Jabar T.I. Khan H.R. Kotadia P. Franciosa |
| author_facet | M.H. Khan S. Jabar T.I. Khan H.R. Kotadia P. Franciosa |
| author_sort | M.H. Khan |
| collection | DOAJ |
| description | Laser beam welding is a critical joining method for wrought 6xxx series aluminium (Al) alloys; however, its broader adoption is hindered by the susceptibility to solidification cracking, which undermines weld integrity and restricts the production of high-quality joints. To mitigate cracking susceptibility, this study explores a novel approach involving the use of alumina (Al2O3) and titanium carbide (TiC) nanoparticles introduced into the fusion zone of laser welded AA6005 aluminium sheets via electrophoretic deposition (CuSO4 bath, ∼40 nm nanoparticles, varying concentrations/times). Microstructural analysis revealed that the incorporation of both Al2O3 and TiC nanoparticles on AA6005 led to an overall 65% grain refinement, effectively preventing centreline cracking during welding. Lap shear testing demonstrated a significant improvement in joint strength, with a 10% increase for Al2O3 coated samples and a 13% increase for TiC coated welds compared to the uncoated material. Notably, TiC outperformed Al2O3 at higher concentrations, exhibiting more uniform dispersion with reduced agglomeration and porosity. In contrast, Al2O3 showed a tendency toward particle clustering and pore formation at elevated concentrations, which limited its strengthening efficiency. This highlights the potential of nanoparticle reinforcement for enhancing the reliability and performance of laser welded 6xxx aluminium alloys. |
| format | Article |
| id | doaj-art-edadfcf8e2124578a706c9fcb112f91b |
| institution | Kabale University |
| issn | 2666-3309 |
| language | English |
| publishDate | 2025-12-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Advanced Joining Processes |
| spelling | doaj-art-edadfcf8e2124578a706c9fcb112f91b2025-08-23T04:49:13ZengElsevierJournal of Advanced Joining Processes2666-33092025-12-011210034410.1016/j.jajp.2025.100344Controlling solidification cracks in laser beam welding of AA6005 using Al2O3 and TiC nanoparticles dispersed in a Cu coatingM.H. Khan0S. Jabar1T.I. Khan2H.R. Kotadia3P. Franciosa4WMG, The University of Warwick, Coventry, CV4 7AL, UK; Corresponding author.WMG, The University of Warwick, Coventry, CV4 7AL, UKSchool of Engineering, The University of Bradford, Bradford, BD7 1DP, UKSchool of Engineering, Liverpool John Moores University, Liverpool L3 3AF, UKWMG, The University of Warwick, Coventry, CV4 7AL, UKLaser beam welding is a critical joining method for wrought 6xxx series aluminium (Al) alloys; however, its broader adoption is hindered by the susceptibility to solidification cracking, which undermines weld integrity and restricts the production of high-quality joints. To mitigate cracking susceptibility, this study explores a novel approach involving the use of alumina (Al2O3) and titanium carbide (TiC) nanoparticles introduced into the fusion zone of laser welded AA6005 aluminium sheets via electrophoretic deposition (CuSO4 bath, ∼40 nm nanoparticles, varying concentrations/times). Microstructural analysis revealed that the incorporation of both Al2O3 and TiC nanoparticles on AA6005 led to an overall 65% grain refinement, effectively preventing centreline cracking during welding. Lap shear testing demonstrated a significant improvement in joint strength, with a 10% increase for Al2O3 coated samples and a 13% increase for TiC coated welds compared to the uncoated material. Notably, TiC outperformed Al2O3 at higher concentrations, exhibiting more uniform dispersion with reduced agglomeration and porosity. In contrast, Al2O3 showed a tendency toward particle clustering and pore formation at elevated concentrations, which limited its strengthening efficiency. This highlights the potential of nanoparticle reinforcement for enhancing the reliability and performance of laser welded 6xxx aluminium alloys.http://www.sciencedirect.com/science/article/pii/S2666330925000652Laser beam welding6005 aluminium alloySolidification crackingNanoparticlesSolidification |
| spellingShingle | M.H. Khan S. Jabar T.I. Khan H.R. Kotadia P. Franciosa Controlling solidification cracks in laser beam welding of AA6005 using Al2O3 and TiC nanoparticles dispersed in a Cu coating Journal of Advanced Joining Processes Laser beam welding 6005 aluminium alloy Solidification cracking Nanoparticles Solidification |
| title | Controlling solidification cracks in laser beam welding of AA6005 using Al2O3 and TiC nanoparticles dispersed in a Cu coating |
| title_full | Controlling solidification cracks in laser beam welding of AA6005 using Al2O3 and TiC nanoparticles dispersed in a Cu coating |
| title_fullStr | Controlling solidification cracks in laser beam welding of AA6005 using Al2O3 and TiC nanoparticles dispersed in a Cu coating |
| title_full_unstemmed | Controlling solidification cracks in laser beam welding of AA6005 using Al2O3 and TiC nanoparticles dispersed in a Cu coating |
| title_short | Controlling solidification cracks in laser beam welding of AA6005 using Al2O3 and TiC nanoparticles dispersed in a Cu coating |
| title_sort | controlling solidification cracks in laser beam welding of aa6005 using al2o3 and tic nanoparticles dispersed in a cu coating |
| topic | Laser beam welding 6005 aluminium alloy Solidification cracking Nanoparticles Solidification |
| url | http://www.sciencedirect.com/science/article/pii/S2666330925000652 |
| work_keys_str_mv | AT mhkhan controllingsolidificationcracksinlaserbeamweldingofaa6005usingal2o3andticnanoparticlesdispersedinacucoating AT sjabar controllingsolidificationcracksinlaserbeamweldingofaa6005usingal2o3andticnanoparticlesdispersedinacucoating AT tikhan controllingsolidificationcracksinlaserbeamweldingofaa6005usingal2o3andticnanoparticlesdispersedinacucoating AT hrkotadia controllingsolidificationcracksinlaserbeamweldingofaa6005usingal2o3andticnanoparticlesdispersedinacucoating AT pfranciosa controllingsolidificationcracksinlaserbeamweldingofaa6005usingal2o3andticnanoparticlesdispersedinacucoating |