Studying the Effect of Laser Welding Parameters on the Quality of ZEK100 Magnesium Alloy Sheets in Lap Joint Configuration

Magnesium has unique properties which makes it superior to many other metals. It has the best strength-to-weight ratio and the lowest density among structural metals. Therefore, it has been used in a variety of industries, including the automotive, aerospace, and electronics industries. However, because of magnesium metallurgical properties, fusion welding poses a significant challenge. Laser welding is one of the most efficient joining processes for welding magnesium alloys because of its low heat input. Low alloy magnesium ZEK100 has been used in the automotive industry; however, little research has been published on the welding of this alloy. In this study, a fiber laser is used to weld samples in a lap joint configuration in order to study the effect of process parameters on weld profile geometry including penetration depth and width on top surfaces and interfaces as well as its quality. Process parameters include laser power, scanning speed and gap between two sheets. Observations include weld bead surface quality, weld bead profile and micro-hardness. The obtained results show that each process parameter has a different effect on weld profile geometry and its quality. Then a regression model is used in order to obtain the geometry of the weld bead based on different process parameters. The performance evaluation of the regression model reveals that a well-related model is established.Magnesium has unique properties which makes it superior to many other metals. It has the best strength-to-weight ratio and the lowest density among structural metals. Therefore, it has been used in a variety of industries, including the automotive, aerospace, and electronics industries. However, because of magnesium metallurgical properties, fusion welding poses a significant challenge. Laser welding is one of the most efficient joining processes for welding magnesium alloys because of its low heat input. Low alloy magnesium ZEK100 has been used in the automotive industry; however, little research has been published on the welding of this alloy. In this study, a fiber laser is used to weld samples in a lap joint configuration in order to study the effect of process parameters on weld profile geometry including penetration depth and width on top surfaces and interfaces as well as its quality. Process parameters include laser power, scanning speed and gap between two sheets. Observations include weld bead s...