Laser beam welding of T joints for aluminum–Copper–lithium aircraft panels: Effect of filler wire on recyclability and weldability

This study assessed the weldability and recyclability of four filler wires, two commercial (ER4047 and ER2319) and two experimental (ER2395 and J300), for laser beam welding of aluminum-Copper-lithium (Al–Cu–Li) aircraft panels. The results showed key differences in porosity and crack formation. The...

Full description

Saved in:
Bibliographic Details
Main Authors: Javier Vivas, Egoitz Aldanondo, Philippe Dufour, Clara Delgado, Ana Isabel Fernández-Calvo
Format: Article
Language:English
Published: Elsevier 2024-11-01
Series:Journal of Materials Research and Technology
Subjects:
Online Access:http://www.sciencedirect.com/science/article/pii/S2238785424024931
Tags: Add Tag
No Tags, Be the first to tag this record!
_version_ 1846107814818217984
author Javier Vivas
Egoitz Aldanondo
Philippe Dufour
Clara Delgado
Ana Isabel Fernández-Calvo
author_facet Javier Vivas
Egoitz Aldanondo
Philippe Dufour
Clara Delgado
Ana Isabel Fernández-Calvo
author_sort Javier Vivas
collection DOAJ
description This study assessed the weldability and recyclability of four filler wires, two commercial (ER4047 and ER2319) and two experimental (ER2395 and J300), for laser beam welding of aluminum-Copper-lithium (Al–Cu–Li) aircraft panels. The results showed key differences in porosity and crack formation. The ER2319 filler exhibited a higher tendency for wormhole-type porosity compared to the others, which had similar pore area fractions. ER2395 displayed the longest crack length, likely due to its high lithium content. Chemical compatibility with the Al–Cu–Li base alloy AA2198 was confirmed for the ER2319, ER2395, and J300 filler wires, enabling 100% closed-loop recyclability without disassembly or alloy sorting. However, the high silicon content (around 11%) of ER4047 resulted in a recycled alloy that exceeded the allowable Si limit for AA2198, making it unsuitable for closed-loop recycling. Several end-of-life (EoL) strategies were explored for scrap fractions from ER4047-welded coupons. The 0C and 1C cutting strategies yielded hybrid fractions incompatible with AA2198 but suitable for the more Si-tolerant AA2196 alloy. The 3C strategy, involving weld seam separation before remelting, optimized recycling rates and minimized environmental impact. Additionally, a pre-scrap characterization method was developed to analyze weld seam composition, allowing for the prediction of recyclability issues and filler wire mass estimation in coupons where both the skin and stringer were made of the same alloy. This method provides a practical approach for evaluating welded structures in future recycling efforts.
format Article
id doaj-art-d3c0ec45a0b348c7ad1e4f0037c12a9a
institution Kabale University
issn 2238-7854
language English
publishDate 2024-11-01
publisher Elsevier
record_format Article
series Journal of Materials Research and Technology
spelling doaj-art-d3c0ec45a0b348c7ad1e4f0037c12a9a2024-12-26T08:55:03ZengElsevierJournal of Materials Research and Technology2238-78542024-11-013358095820Laser beam welding of T joints for aluminum–Copper–lithium aircraft panels: Effect of filler wire on recyclability and weldabilityJavier Vivas0Egoitz Aldanondo1Philippe Dufour2Clara Delgado3Ana Isabel Fernández-Calvo4LORTEK Technological Centre, Basque Research and Technology Alliance (BRTA), Arranomendia kalea 4A, 20240, Ordizia, Spain; Corresponding author.LORTEK Technological Centre, Basque Research and Technology Alliance (BRTA), Arranomendia kalea 4A, 20240, Ordizia, SpainSociété Nationale de Construction Aérospatiale, SONACA SA, 6041, Gosselies, BelgiumAZTERLAN, Basque Research and Technology Alliance (BRTA), E-48200, Durango, SpainAZTERLAN, Basque Research and Technology Alliance (BRTA), E-48200, Durango, SpainThis study assessed the weldability and recyclability of four filler wires, two commercial (ER4047 and ER2319) and two experimental (ER2395 and J300), for laser beam welding of aluminum-Copper-lithium (Al–Cu–Li) aircraft panels. The results showed key differences in porosity and crack formation. The ER2319 filler exhibited a higher tendency for wormhole-type porosity compared to the others, which had similar pore area fractions. ER2395 displayed the longest crack length, likely due to its high lithium content. Chemical compatibility with the Al–Cu–Li base alloy AA2198 was confirmed for the ER2319, ER2395, and J300 filler wires, enabling 100% closed-loop recyclability without disassembly or alloy sorting. However, the high silicon content (around 11%) of ER4047 resulted in a recycled alloy that exceeded the allowable Si limit for AA2198, making it unsuitable for closed-loop recycling. Several end-of-life (EoL) strategies were explored for scrap fractions from ER4047-welded coupons. The 0C and 1C cutting strategies yielded hybrid fractions incompatible with AA2198 but suitable for the more Si-tolerant AA2196 alloy. The 3C strategy, involving weld seam separation before remelting, optimized recycling rates and minimized environmental impact. Additionally, a pre-scrap characterization method was developed to analyze weld seam composition, allowing for the prediction of recyclability issues and filler wire mass estimation in coupons where both the skin and stringer were made of the same alloy. This method provides a practical approach for evaluating welded structures in future recycling efforts.http://www.sciencedirect.com/science/article/pii/S2238785424024931Laser beam weldingMetal recyclingAluminum–copper–lithium alloysRecycling of welded structuresWeldabilityEnd of life of aircraft panels
spellingShingle Javier Vivas
Egoitz Aldanondo
Philippe Dufour
Clara Delgado
Ana Isabel Fernández-Calvo
Laser beam welding of T joints for aluminum–Copper–lithium aircraft panels: Effect of filler wire on recyclability and weldability
Journal of Materials Research and Technology
Laser beam welding
Metal recycling
Aluminum–copper–lithium alloys
Recycling of welded structures
Weldability
End of life of aircraft panels
title Laser beam welding of T joints for aluminum–Copper–lithium aircraft panels: Effect of filler wire on recyclability and weldability
title_full Laser beam welding of T joints for aluminum–Copper–lithium aircraft panels: Effect of filler wire on recyclability and weldability
title_fullStr Laser beam welding of T joints for aluminum–Copper–lithium aircraft panels: Effect of filler wire on recyclability and weldability
title_full_unstemmed Laser beam welding of T joints for aluminum–Copper–lithium aircraft panels: Effect of filler wire on recyclability and weldability
title_short Laser beam welding of T joints for aluminum–Copper–lithium aircraft panels: Effect of filler wire on recyclability and weldability
title_sort laser beam welding of t joints for aluminum copper lithium aircraft panels effect of filler wire on recyclability and weldability
topic Laser beam welding
Metal recycling
Aluminum–copper–lithium alloys
Recycling of welded structures
Weldability
End of life of aircraft panels
url http://www.sciencedirect.com/science/article/pii/S2238785424024931
work_keys_str_mv AT javiervivas laserbeamweldingoftjointsforaluminumcopperlithiumaircraftpanelseffectoffillerwireonrecyclabilityandweldability
AT egoitzaldanondo laserbeamweldingoftjointsforaluminumcopperlithiumaircraftpanelseffectoffillerwireonrecyclabilityandweldability
AT philippedufour laserbeamweldingoftjointsforaluminumcopperlithiumaircraftpanelseffectoffillerwireonrecyclabilityandweldability
AT claradelgado laserbeamweldingoftjointsforaluminumcopperlithiumaircraftpanelseffectoffillerwireonrecyclabilityandweldability
AT anaisabelfernandezcalvo laserbeamweldingoftjointsforaluminumcopperlithiumaircraftpanelseffectoffillerwireonrecyclabilityandweldability