Hot cracking in Al–Mg–Si alloy laser welding – operating parameters and their effects

Hot cracking is a phenomenon that frequently occurs in the laser welding of some “special” alloys, such as the aluminium–magnesium–silicon type. Each occurrence of this phenomenon needs to be studied in itself, taking into account not only the individual, but also the interactive, influences of the various parameters. The advantage of using laser beams in welding processes lies in the speeds that can be reached. The disadvantage, however, is that, owing to the high cooling rates characteristic of the interaction between the laser beam and the material, the welding speed itself becomes a cause of hot cracking. The aim of this paper is to see how this disadvantage may be eliminated. We consider what the most important parameters may be, relating to tensile strength and the quantity of cracks produced, that might influence the presence or absence of hot cracking. The most influential factors in avoiding hot cracking are the welding speed and wire parameters. Also important is welding stability, as instability generates cracks. We can then determine a technological window, useful for industrial applications, which takes into account the values of these influential factors and stability.