Journal Article/Contribution to a conference proceedings

PUBDB-2026-02974

http://join2-wiki.gsi.de/foswiki/pub/Main/Artwork/join2_logo100x88.png Synchrotron X-ray imaging of the formation of transverse hot cracks during laser welding of a high-strength aluminum alloy and their dependence on local solidification conditions and process parameters

Michel, J. (Corresponding author)Extern* ; Haas, M.Extern* ; Steinhoff, R.Extern* ; Sawannia, M.Extern* ; Spurk, C.Extern* ; Hummel, M.Extern* ; Olowinsky, A.Extern* ; Beckmann, F.Hereon* ; Moosmann, J.Hereon* ; Hagenlocher, C.Extern* ; Graf, T.

2026
Elsevier Amsterdam [u.a.]

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Please use a persistent id in citations: doi:10.1016/j.procir.2026.07.040  doi:10.3204/PUBDB-2026-02974

Abstract: The formation of transverse hot cracks in the weld seam limits the use of laser welding for high-strength aluminum alloys in lightweight electromobility applications. While transverse hot cracks initiate in the semisolid region, their exact location relative to the melt pool boundary and their relation to local solidification conditions and process parameters remain unclear. In this study, the formation of transverse hot cracks was investigated using in-situ synchrotron X-ray imaging. Crack initiation and propagation relative to the melt pool boundary, crack propagation rates, solidification rates, and the number of transverse cracks in the weld seam were evaluated as a function of welding speed and laser power. The results show that the average crack propagation rate corresponds to the local solidification rate along the melt pool boundary encountered during propagation. Increasing welding speed at constant weld depth increased both the crack propagation rate and the number of cracks in the weld seam. Reduced laser power at a constant welding speed resulted in higher crack propagation rates and more, but shallower, cracks. The findings advance the understanding of the mechanisms underlying transverse hot cracking and provide a basis for developing mitigation strategies.

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Contributing Institute(s):

1. DOOR-User (DOOR)
2. Helmholtz-Zentrum Hereon (Hereon)

Research Program(s):

1. 6G3 - PETRA III (DESY) (POF4-6G3) (POF4-6G3)
2. FS-Proposal: BAG-20211050 (BAG-20211050) (BAG-20211050)
3. DFG project G:(GEPRIS)558591047 - Multikriterielle, prozessübergreifende Auslegung für den Herstellprozess von Aluminium-Kühlplatten auf Basis der ganzheitlichen Modellierung der Prozesskette Umformen/Laserschweißen (558591047) (558591047)
4. DFG project G:(GEPRIS)236616214 - SFB 1120 Bauteilpräzision durch Beherrschung von Schmelze und Erstarrung in Produktionsprozessen (236616214) (236616214)

Experiment(s):

1. PETRA Beamline P07 (PETRA III)

Appears in the scientific report 2026

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Database coverage:
; ; ; SCOPUS

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