Oscillating laser hot-wire welding morphology quality control of aluminum alloys

This paper experimentally investigated the effects of laser beam oscillation and hot-wire process parameters on the surface and cross-sectional morphologies of aluminum alloy welds during oscillating laser hot-wire welding. The study revealed a competitive relationship between laser beam oscillation and the hot-wire in influencing weld morphology. As the hot-wire current increases, the weld surface quality initially improves and then deteriorates, with spatter gradually increasing and weld penetration (depth of fusion) first increasing and then decreasing. Similarly, as the oscillation frequency rises, surface quality improves and then declines, spatter decreases and then slightly increases, and the weld penetration gradually decreases. Optimal process parameters were identified within the studied range, achieving a weld with high penetration, excellent surface quality, minimal spatter, and high weld stability by coupling the effects of laser beam oscillation and hot-wire input.