Enhanced strength and ductility of aluminum alloy laser welded joints through Ca micro-alloyed welding materials

Aluminum alloy is widely used in high-speed train bodies. However, compared with the base material, the tensile strength and elongation of its laser welded joints are significantly reduced, which limits the lightweight application of the next generation of high-speed trains. The research in this article indicates that laser welding with Ca micro-alloyed 5356 filler metal has changed the mechanical properties and microstructure of the weld seam. Without the Ca in the filler metal, the strength and elongation of the laser welded joint are only 215.5 MPa and 3.1 %. When the Ca content in the filler metal reaches 0.04 wt%, the laser welded joint has high tensile strength and maximum elongation, which are 251.5 MPa and 9.7 %, respectively. As the Ca content increases, the grain size of the welded joint gradually decreases, and the limiting effect of Ca element on the growth of alpha- Al grains is the main reason for grain refinement. In addition, the addition of Ca transforms the coarse Fe-rich phase in the weld into a fine-grained second phase, while promoting the formation of deformable nanoparticles gamma- Al12Mg17, leading to the accumulation of dislocations and successfully improving the strength and plasticity of laser welded joints. When the Ca content further increases, the second phase grows, and the tensile strength and plasticity of the joint slightly decrease, but are still higher than that of the joint without Ca.