Filler wire for laser-welding aluminum alloy member, method of welding aluminum alloy member by using the filler wire, and welded-aluminum alloy member produced by using the filler wire

• US 20020012810A1
• Filed: 06/12/2001
• Published: 01/31/2002
• Est. Priority Date: 06/12/2000
• Status: Active Grant

• Current Assignee: Nissan Motor Co., Ltd., Showa Denko KK
• Original Assignee: Nissan Motor Co., Ltd.
• Inventors: Sakamoto, Hiroki, Suzuki, Kenji, Tsushima, Kenji, Hashimoto, Takenori, Osame, Yasuhiro
• Granted Patent: US 6,548,191 B2
• Time in Patent Office: Days
• US Class Current: 428/650
• CPC Class Codes: B23K 2103/10 Aluminium or alloys thereof
• CPC Class Codes: B23K 26/0604 by a combination of beams
• CPC Class Codes: B23K 26/211 with interposition of special material to facilitate connection of the parts
• CPC Class Codes: B23K 26/32 taking account of the properties of the material involved
• CPC Class Codes: B23K 35/0244 Powders, particles or spheres; Preforms made therefrom
• CPC Class Codes: B23K 35/286 Al as the principal constituent
• CPC Class Codes: B23K 35/3605 Fluorides
• CPC Class Codes: B32B 15/016 all layers being formed of aluminium or aluminium alloys
• CPC Class Codes: Y10S 428/934 Electrical process
• CPC Class Codes: Y10T 428/12229 Intermediate article [e.g., blank, etc.]
• CPC Class Codes: Y10T 428/12479 Porous [e.g., foamed, spongy, cracked, etc.]
• CPC Class Codes: Y10T 428/12736 Al-base component
• CPC Class Codes: Y10T 428/12764 Next to Al-base component
• CPC Class Codes: Y10T 428/2951 Metal with weld modifying or stabilizing coating [e.g., flux, slag, producer, etc.]

Abstract

A filler wire for laser-welding an aluminum alloy is described, which comprises a base material of Aluminum-Silicon based alloy and a flux of Aluminum-Potassium-Fluorine-based composition. The amount of the flux in the base material is greater than 0 (zero) wt. % and less than approximately 1.0 wt. %.

Claims

1. A filler wire for laser-welding an aluminum alloy, comprising:

a base material; and

a flux of Al—

K—

F (viz., Aluminum-Potassium-Fluorine)-based composition,

wherein the amount of said flux in said base material is greater than 0 (zero) wt. % and less than approximately 1.0 wt. %.

2. A filler wire as claimed in claim 1, in which the amount of the flux in the base material is not less than 0.05 wt. %.

3. A filler wire as claimed in claim 2, in which the amount of the flux in the base material is approximately 0.5 wt. %.

4. A filler wire as claimed in claim 1, in which said base material is an Al—

Si (viz., Aluminum-Silicon)-based alloy.

5. A filler wire as claimed in claim 4, in which said base material is selected from at least one of the materials of the group consisting of Al-10%Si alloy, JIS-4043 alloy and JIS-4047 alloy.

6. A filler wire as claimed in claim 1, in which said flux is selected from at least one of the materials of the group consisting of KAlF₄, K₂AlF₅, K₃AlF₆, a mixture of KF and AlF₃, an eutectic composition of KF and AlF₃, and fluoroamine acid potassium complex.

7. A method of welding a work piece of aluminum alloy, comprising:

preparing the work piece of aluminum alloy; and

laser-welding said work piece by using a filler wire, said filler wire comprising a base material and a flux of Al—

K—

F (viz., Aluminum-potassium-fluorine)-based composition, the amount of said flux in said base material being greater than 0 (zero) wt. % and less than approximately 1.0 wt. %.

8. A method as claimed in claim 7, in which said work piece to be welded is an Al—

Si-based alloy or an Al—

Mg—

Si-based alloy.

9. A method as claimed in claim 8, in which the laser welding is carried out under a condition wherein the laser output is approximately 4.0 Kw, welding speed is approximately 6.0 to 8.0 m/min. and feeding speed of the filler wire is approximately 6.0 to 8.0 m/min.

10. A method as claimed in claim 7, in which said work piece to be welded is an Al-11%Si-0.5% die casting alloy, and in which the laser welding is carried out under a condition wherein double laser beams having outputs of approximately 3.0 Kw and 2.0 Kw are converged on the work piece, the distance between the double laser beams is approximately 0.6 mm, welding speed is approximately 6.0 m/min. and feeding speed of the filler wire is approximately 5.3 m/min.

11. A welded-aluminum alloy member produced by the process comprising the steps of preparing an aluminum alloy;

and laser-welding said aluminum alloy by using a filler wire, said filler wire comprising a base material and a flux of Al—

K—

F (viz., Aluminum-potassium-fluorine)-based composition, the amount of said flux in said base material being greater than 0 (zero) wt. % and less than approximately 1.0 wt. %.

12. A welded-aluminum alloy member as claimed in claim 11, in which said aluminum alloy is an aluminum alloy casting member or aluminum alloy die casting member.

13. A welded-aluminum alloy member as claimed in claim 11, in which the porosity at a welded portion of the aluminum alloy is less than 10%.