| Abstract Scope |
Joining of thin sheet metals has traditionally had challenges with melt-through, cracking, and distortion, all of which are of particular concern with aluminum alloys. Gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW) processes have low heat input waveforms yet still have thermal input challenges with thin gauge materials. Hybrid laser arc welding (HLAW) is another process used for joining thin sheet, but distortion remains an issue due to high thermal input. Autogenous laser beam welding (LBW) is widely used for thin sheet metals as well, but high tolerance fit-up requirements make it too costly and slow for the automotive industry. Hotwire laser welding (HWLW) is a novel joining method that has been developed to achieve acceptable fusion for thin sheet metals, while minimizing heat input and distortion. This is achieved by suppressing the arc associated with other processes so that resistive heating and laser power are the only sources of heat input. Additionally, the added wire overcomes fit-up issues of LBW. The following work shows progress made in development of HWLW of thin sheet Al 6061-T6 for use in electric vehicle battery trays, and forecasts upcoming work and development related to this project. |