Pore formation mechanism and its mitigation in laser welding of AZ31B magnesium alloy in lap joint configuration

• Decomposition of magnesium hydroxide is considered the main mechanism causing pores.
• Preheating samples prior to laser welding could effectively mitigate pore formation.
• The behavior of the molten pool as well as plasma plume are studied.
• Tensile test results revealed that preheated samples have a higher value.
• In adjacent weld lines, larger pores are formed in the sides weld beads.

Magnesium is one of the lightest structural metals that has been used in different industries such as automobile, aerospace and electronics. However, in fusion joining of magnesium alloys, porosity is one of the main drawbacks to achieve a weld with desirable properties. The oxide layer existing on the surface of magnesium alloy is one of the causes of pore formation in the weld bead. In the current study, a fiber laser with a power of up to 4 kW is used to weld samples in a zero-gap lap joint configuration. Two groups of samples are studied: as-received (AR) surfaces (where an oxide layer remains on the surface) and treated surfaces. The surface treatment includes two techniques: mechanically removed (MR) and the use of a plasma arc (PA) as a preheating source. Also, a separate set of experiments are designed for preheating samples in a furnace for comparison with the PA-treated results. To reveal the chemical compositions of the welds and metal sheet surfaces, an energy dispersive spectroscopy (EDS) is performed. Surface chemical compositions are tested by X-ray photoelectron spectroscopy-reflected electron energy loss spectroscopy (XPS-REELS) to characterize the surface composition on AR and PA-treated samples. The dynamic behavior of the weld pool and laser-induced plasma plume is monitored in real-time using a high speed CCD camera to investigate the stability of the laser welding process. The presence of the oxide layer at the faying surface of two overlapped sheets results in an unstable process. The obtained results reveal that the preheating procedure can effectively mitigate pore formation at the interface of the two overlapped sheets.