Study of local-zone microstructure, strength and fracture toughness of hybrid laser-metal-inert-gas-welded A7N01 aluminum alloy joint

Mechanical properties of hybrid laser-metal-inert-gas-welded A7N01-T5 aluminum alloy joints were studied by using local samples that were extracted from the base metal (BM), heat-affected zone (HAZ), and fusion zone (FZ) of the joint to investigate the triangular relationship of microstructure, strength and fracture toughness of the local zones. The BM had the highest yield strength, ultimate tensile strength (UTS) and lowest elongation, which contrasts with the FZ. The yield strength of the HAZ is lower than that of the BM, whereas its UTS is very close to that of the BM, and its elongation is higher than that of the BM. The fracture toughness of the three local zones decreased as HAZ > BM > FZ. To analyze differences in local mechanical behavior, the detailed microstructure of the three local zones was studied by optical microscopy and electron backscattered diffraction, whereas the fracture surface and precipitation were studied by scanning and transmission electron microscopy. The variation of grain size, especially the morphology and distribution of strengthening phase in HAZ in welding process is the key factor that leads to its different mechanical properties from that of BM, which can be elucidated by different dislocation mechanism, sheared mechanism or Orowan mechanism. The as-cast microstructure and second-phase particles that segregate between dendritic branches provide the FZ with the lowest yield strength and UTS. The factors including area fraction of the precipitates, the difference of strength between the matrix and the grain boundaries, the precipitate-free zone along grain boundaries, as well as the grain boundaries angle are taken into account to explain the difference of fracture toughness among BM, HAZ and FZ, and their fracture modes.