Effect of kerf characteristics on weld porosity of laser cutting-welding of AA2219 aluminum alloy

Abstract The purification of laser keyhole and improving molten pool flow are important means to restrain the porosity of laser-MIG hybrid welding of aluminum alloy. In this paper, four kinds of kerf were prefabricated by four common gases (Argon, Nitrogen, Air, Oxygen), which are used for studying the effect of kerf remelted layer on weld porosity. The experimental results show that the porosity is affected by the composition and thickness of the remelted layer. The porosity of Argon-weld and Nitrogen-weld is low, and that of Air-weld and Oxygen-weld is high. It increased linearly with the thickness of remelted layer (d). Regardless of the types of kerf, when the d is less than 136 μm, the porosity is less than 2%. When the d is thin, the purification of laser keyhole avoids the adverse effect of remelted layer oxide on the molten pool and reduces the porosity. When the d is thick, the influence of oxygen on surface tension and molten pool flow driven by it starts to dominate. It makes the temperature coefficient of surface tension change from negative to positive, and the molten pool change from ‘outward flow’ to ‘inward flow’, which prevent bubbles from escaping and increasing the porosity.