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...
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Elsevier
2024-11-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785424024931 |
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| 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 |
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| 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 |
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