Materials and Design 32 (2011) 44084416

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Materials and Design

journal homepage: www.elsevier.com/locate/matdes

Improving interfacial reaction nonhomogeneity during laser weldingbrazing

aluminum to titanium
Shuhai Chen a,b,, Liqun Li b, Yanbin Chen b, Jingmin Dai c, Jihua Huang a
a

School of Materials Science and Engineering, University of Science and Technology Beijing, Beijing 100083, PR China
State Key Laboratory of Advanced Welding Production Technology, Harbin Institute of Technology, Harbin 150001, PR China
c
School of Electrical Engineering and Automation, Harbin Institute of Technology, Harbin 150001, PR China
b

a r t i c l e

i n f o

Article history:
Received 12 October 2010
Accepted 30 March 2011
Available online 8 April 2011
Keywords:
Lasers
Welding
Brazing

a b s t r a c t
Heterogeneous interfacial reactions were easily found along the Ti/Al interface due to high temperature
gradient during laser weldingbrazing of Ti/Al dissimilar alloys. To improve the nonhomogeneity, relative
uniform energy distribution of laser beam and appropriate groove were attempted. The effects of these
attempts on the nonhomogeneity of interfacial reactions were investigated by nite element method
(FEM) numerical simulation and experimental validation. The results indicate that the V-shaped groove
can make the interface roughly parallel to the isotherm of the temperature eld. Moreover, the rectangular spot laser can further improve homogenization of the interfacial reaction along the interface in
comparison with circular spot laser. Tensile test results show that the combination of rectangular spot
laser weldingbrazing and V-shaped groove can effectively control the fracture of Ti/Al joints in the seam
in a wide processing parameters window, and the average tensile strength reaches 278 MPa.
2011 Elsevier Ltd. All rights reserved.

1. Introduction
Lightweight hybrid structures of Ti/Al dissimilar alloys have
great prospect in aerospace and automotive industry applications
[1,2]. It is necessary to join aluminum with titanium to achieve this
structural design. However, welding of Al/Ti dissimilar alloys is
rather difcult due to their large difference in thermophysical
and thermochemical performances. The formation of large amount
of brittle intermetallic compounds is a big problem during the
joining of Ti/Al. Therefore, diffusion welding [3], brazing [4] and
friction stir welding [57] were investigated to control the formation of brittle intermetallic compound, but these methods were
restricted by vacuum environment or joint conguration.
In recent years, arc weldingbrazing [810] has been developed
for partners with large difference in melting point. Compared with
the arc, laser was regarded as desirable heating source for joining
dissimilar alloys [1113], such as high energy density and high
heating/cooling velocity. Laser weldingbrazing has shown good
prospect in application of the joining of Fe/Al dissimilar alloys
[14,15]. The thickness of brittle reaction layer can be limited to
the level of just a few microns in laser weldingbrazing of Al/Ti,
which can signicantly enhance the mechanical property of the
joint [1621]. Moreover, laser weldingbrazing is a very exible

Corresponding author at: School of Materials Science and Engineering, University of Science and Technology Beijing, Beijing 100083, PR China. Tel.: +86 010
62334859.
E-mail addresses: shchenhit@gmail.com, shchen@mater.ustb.edu.cn (S. Chen).
0261-3069/$ - see front matter 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2011.03.074

manufacturing technique and it is convenient for industrial

application.
However, there is an enormous gradient inside the joint because
laser weldingbrazing is a local heating, which can result in a series
of problems, such as interfacial reaction nonhomogeneity, poor
welding process and poor spreadability of brazing ller metal. In
order to solve these problems, laser brazing with hot ller wire
[22], dual beam laser brazing [23] and diode laser brazing [24] have
been developed. Unfortunately, interfacial reaction nonhomogeneity along the interface from the top to the bottom of the joint is still
not solved. Interfacial reaction nonhomogeneity may induce the fact
that interfacial reaction is overly performs at the top of the joint,
whereas it is insufcient at the bottom of the joint. Therefore, this
nonhomogeneity is unfavorable for enhancing the controllability
of interfacial reaction and the controlling of mechanical properties,
especially for butt welding of dissimilar alloys.
The goal of this paper is to improve the nonhomogeneity of
interfacial reaction of Al/Ti joint by laser weldingbrazing. Both
rectangular spot laser beam with relative uniform energy distribution and V-shaped groove with 45 angle were used to decrease the
temperature gradient along the interface. The temperature eld,
distribution of intermetallic compounds, tensile strength and fracture behavior of joints were described.
2. Materials and experimental procedure
Ti6Al4V alloy and 5A06 Al alloy plates with a thickness of
1.5 mm were selected as the laser joining materials. 5A06 Al alloy

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S. Chen et al. / Materials and Design 32 (2011) 44084416

Table 1
Mechanical property of base materials.
Alloys
5A06
Ti6Al4V

Tensile strength

Offset yield
strength r0.2 (MPa)

Elongation (%)

rb (MPa)
315
895

160
825

15
10

plates were a non-heat treatable antirust Al alloys. 5A06 alloy was

composed of a solid solution, b phase (Al3Mg2) and b phase
(Mg23Al30). The production of 5A06 plate was accord with GB/T
6892-2000, which is close to ASTM B209-04 [25]. The mill annealed sheet of Ti6Al4V alloy used here was a-b titanium alloy
containing around 930% b phase. The production of Ti6Al4V
plate was accord with ASTM B26510 [26]. To suppress Ti/Al reaction layer growth [4], Al12Si ux-cored wire with the diameter of
2 mm was used as ller metal. The production of ller wire was accord with the mechanical properties of the base materials are listed
in Table 1. And the chemical compositions of base materials and ller wire are shown in Table 2.
Base materials were cleaned prior to joining experiment. Al alloy specimens were soaked in acetone for 3 min, 20% (in mass)
NaOH solution for 8 min, 30% (in mass) HNO3 solution for 5 min
and clear water for 10 min, respectively. The specimens were then
dried at 60 C for 30 min. Ti alloy specimens were soaked in acetone for 3 min, 40% HNO3 + 5% HF (in mass) solution for 5 min
and clear water for 10 min, respectively. Then, the specimens were
dried at 120 C for 30 min.
To promote uniform interfacial reaction, two ways were suggested in this paper. Firstly, V-shape groove was processed on parent metal, which can ensure that the interface roughly parallels to
the isotherm of temperature eld, which may reduce the temperature gradient along the whole interface. Secondly, relative uniform temperature eld was obtained by transforming the energy
distribution of the laser spot. In this paper, circular laser spot with
Gaussian energy distribution was modulated to rectangular spot
(2 mm  4 mm) with relative uniform energy distribution by a
integral mirror. The rectangular spot has uniform energy distribution along longer side and Gaussian energy distribution along
shorter side. Longer side is perpendicular to welding direction during the laser weldingbrazing.
Fig. 1 shows the schematic of the laser weldingbrazing processing. Double shielding argon gas (purity 99.99%) was used to
avoid the oxidation of the liquid ller, the matrix and at the same
time to improve the wetting behavior in the back of the matrix. The
laser beam irradiated vertically towards the workpiece. The angle
of the ller wire and the workpiece was adjusted to 30. Focal spot
of laser beam with circular spot was located at 45 mm over upper
surface of the specimen, and focal spot location of laser beam with
rectangular spot coincided with upper surface of the specimen. Filler wire was fed in front of the laser beam. The laser beam moved
an appropriate distance from the seam center line to Al metal base
due to difference in heat conductivity and the reectance of Ti and
Al alloys. In this paper, optimal offset of laser beam was obtained
by FEM numerical simulation.
The microstructure of joints was observed by optical microscope (OM) and scanning electron microscope (SEM) equipped

Fig. 1. Schematic diagram of the laser weldingbrazing Ti/Al dissimilar alloys.

with an energy-dispersive X-ray spectrometer (EDS) after standard

grinding and polishing procedures and etching with mixed solution (1 vol.% HF + 1.5 vol.% HCl + 2.5 vol.% HNO3 + 95 vol.% H2O).
The tensile strengths at room temperature of the specimens (sample size 10 mm  50 mm) were evaluated by a testing machine
(INSTRON MODEL 1186) at a cross head speed of 1 mm/min. To
evaluate accurately the tensile strength of these samples and avoid
the inuence of excess weld metal, these joints were ground to at.
3. Results and discussion
3.1. FEM numerical simulation
3.1.1. FEM conditions
A three dimensional (3D) nite element model was implemented in the nite element software MARC with a Fortran
subroutine to simulate moving heat source. During laser weldingbrazing, most of laser spot was deposited onto weld pool surface due to continuous lling of the wire whereas only small of
laser spot was deposited onto Ti alloy surface. Therefore, the heat
source was considered to be deposited onto the weld surface with
both of the circular (diameter: 4 mm) and the rectangular spots
(size: 2 mm  4 mm for FEM simulation.). Because laser welding
brazing has high heating/cooling velocity and high temperature
gradient, ne mesh was generated near the seam zone and the
coarse mesh was generated far from the seam zone by eight nodes
and hexahedron, as shown in Fig. 2.
In the numerical simulation, the latent heat of fusion from ller
and partially melting aluminum base was taken into account by
equivalent specic heat method. The heat transfer effect was
achieved through increasing heat conductivity from the top to
the end of weld pool when the contribution of convection ow
from liquid ller metal was considered [27].
3.1.2. FEM results
The aim of FEM simulation was to determine the inuence
of laser spot modes on the distribution characteristics of the

Table 2
Compositions of 5A06 Al, Ti6Al4V alloy and ller metal used in this study.
Alloys

5A06
Ti6Al4V
Filler wire

Elements (wt.%)
Al

Ti

Mg

Si

Cu

Mn

Fe

Zn

Bal.
5.56.8
Bal.

0.02
Bal.
0.15

5.86.8

0.1

0.4

12.0

0.1

0.3

0.50.8

0.15

0.4
0.3
0.8

0.2

0.2

3.54.5

0.1

0.05

0.01

0.2

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S. Chen et al. / Materials and Design 32 (2011) 44084416

Fig. 2. Generated mesh of laser weldingbrazing joint, (a) whole generated mesh, (b) generated mesh of joint cross-section.

temperature eld. The study on this inuence is benecial to identify the best laser spot mode for improving interfacial reaction
nonhomogeneity. In addition, FEM simulation can optimize the
process parameter, such as the offset of laser beam.
Fig. 3 shows a temperature eld of the laser weldingbrazing
process under the condition of the circular spot. The simulation
parameters are respectively laser power of 1400 W, the offset of
laser beam of 0.6 mm, welding speed of 0.5 m/min and ller wire
speed of 2.0 m/min. The temperature distribution exhibits an
obviously asymmetric characteristic. High temperature area at
the Al side is wider than that of the Ti side, as shown in Fig. 3a.
The reason for this is that the heat conductivity of Al alloy outclasses that of Ti alloy. Therefore, the amount of thermal energy

absorbed by Ti and Al alloys should be properly redressed based

on corresponding heating condition to improve weld appearance,
wettability of liquid ller on the base metal and interfacial reaction
nonhomogeneity. In this investigation, heat absorption distribution between Ti and Al alloys was adjusted by the offset of laser
beam toward Al alloy. According to the FEM numerical simulation,
optimal offset of laser beam is 0.6 mm for circular spot.
Fig. 3b shows a temperature distribution of a joint along the
section-cross. It is clear that the interface and isotherms of temperature eld intersect at small angles by using of the V-shaped
groove. It is shown that the V-shaped groove has the tendency of
making them parallel. As a result, this method can clearly promote
homogenization of the interfacial reaction. However, there is still

S. Chen et al. / Materials and Design 32 (2011) 44084416

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Fig. 3. Temperature eld simulation for laser weldingbrazing joint by circular spot, (a) upper surface of the seam, (b) cross-section of the joint.

higher temperature gradient along the interface. Therefore, it is an

indication that interfacial reaction nonhomogeneity should be further improved.
Rectangular spot laser weldingbrazing process was numerically simulated by FEM to further improve interfacial reaction nonhomogeneity. Fig. 4 shows a result of the numeration simulation.
The simulation parameters are respectively laser power of
2400 W, the offset of laser beam of 0.4 mm, welding speed of
0.5 m/min and ller wire speed of 2.0 m/min. The characteristic
of temperature distribution for rectangular spot is similar with that
of circular spot at upper part of the seam, as shown in Fig. 4a.
According to numeration simulation, optimal offset of laser beam
is 0.4 mm for rectangular spot.
Fig. 4b exhibits a temperature distribution of a joint alone the
cross-section under the condition of rectangular spot with relative

uniform energy distribution. It is observed that the interface is

roughly parallel with the isotherm of temperature eld. The temperature along interfacial zone roughly exhibits a uniform distribution compared with the circular spot. Therefore, rectangular spot
laser weldingbrazing can obtain more uniform interfacial reaction. This may play a positive role in the controllability of interfacial reaction and mechanical properties of the joint.
3.2. Inuence of laser spot mode on interfacial reaction
nonhomogeneity
The numerical simulation results indicate that interfacial reaction nonhomogeneity can be improved by rectangular spot laser
weldingbrazing combined with V-shaped groove. The laser weldingbrazing experiments were performed under the condition of

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S. Chen et al. / Materials and Design 32 (2011) 44084416

Fig. 4. Temperature eld simulation for laser weldingbrazing joint by rectangular spot, (a) upper surface of the seam, (b) cross-section of the joint.

same parameters with FEM simulations. In order to expediently

analyze the inuence of heat source mode on interfacial reaction
at same location, the observation zone for every joint is shown in
Fig. 5. Zone A locates the top of the Ti groove. The distances of A,
B and C are 0.38 mm along through-thickness direction. D zone is
at the end of the Ti groove.
Fig. 6a and b shows thermal cycle curves extracted from FEM
simulation results corresponding to A, B, C and D zones for the
joints by rectangular and circular spots, respectively. On the
one hand, interaction time of solid/liquid is roughly equal for
the same laser spot mode. Therefore, the thickness of reaction
layer should depend on the peak temperature at the interface
for same laser spot mode. On the other hand, it is obvious that
the difference in the peak temperature between zone A and D
of the joint by circular spot (1000.83772.93 C) is higher than

that by rectangular spot (1013.21950.26 C). That indicates that

laser weldingbrazing with rectangular spot can promote relatively uniform interfacial reaction along the interface compared
with circular spot. In addition, it is also found that the interaction
time at high temperatures during rectangular spot laser welding
brazing is shorter than that of circular spot. This is because that
the heating length along welding direction in rectangular spot
is less than that of circular spot.
Figs. 7 and 8 display interfacial microstructure of rectangular
and circular spot laser weldingbrazing at above-mentioned corresponding zone, respectively. Obviously, interfacial microstructures
of joint prepared with rectangular spot have relatively uniform distribution than that of circular spot. Therefore, it seems safe to conclude that the joint produced by rectangular spot mode has relative
uniform interfacial reaction.

S. Chen et al. / Materials and Design 32 (2011) 44084416

4413

Fig. 5. Observation region of V-shaped groove joint at interface.

To further prove this result, laser weldingbrazing experiments

were performed under the condition of other process parameters.
Temperature distribution is sensitive to the offset of laser beam
in all process parameters. Thus, the offsets of circular and rectangular laser beam were revised as 0.4 mm and 0.2 mm and other
process parameters were same with that of FEM numerical simulation. The results are shown in Figs. 9 and 10. In the case of circular
spot, the thickness of the reaction layer at the zone A outclasses
that of the zone D. In fact, interfacial reaction mode has transformed to melting mode from dissolution mode. Interfacial reaction mechanism and microstructures has been reported in detail
elsewhere [21,28]. The local thick reaction layer plays a negative
role on the mechanical properties of the join, even with thin layers
in other zones, the process parameter is unusable. The local thick
reaction layer increases the residual stress, which may induce
crack initiation, and can increase the brittleness of the joint [20].
In contrast, the thickness of the reaction layer still keeps relative
uniform under rectangular laser spot. Therefore, process parameter

Fig. 6. Calculated results of thermal cycle at the interface, (a) circular spot, (b)
rectangle spot.

Fig. 7. Interfacial microstructures of the joints by circular spot, (a) zone A, (b) zone B, (c) zone C, (d) zone D.

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S. Chen et al. / Materials and Design 32 (2011) 44084416

Fig. 8. Interfacial microstructures of the joints by rectangular spot, (a) zone A, (b) zone B, (c) zone C, (d) zone D.

Fig. 9. Interfacial microstructures of the joints by circular spot under offset of laser beam 0.4 mm, (a) zone A, (b) zone B, (c) zone C, (d) zone D.

of rectangular spot is still usable while laser beam moves 0.2 mm

toward Ti base from optimal offset for rectangular and circular
spot, respectively. It indicates that usable process parameter range
of rectangular spot laser weldingbrazing is wider than that of circular spot.

The butt joining of Ti/Al dissimilar alloys is difcult for laser

weldingbrazing due to controllability of interfacial reaction and
spreadability of liquid metal. Kreimeyer et al. [16] suggested that
laser melted the titanium base metal while heating the aluminum
base metal through the heat conduction, but this method has

S. Chen et al. / Materials and Design 32 (2011) 44084416

4415

Fig. 10. Interfacial microstructures of the joints by rectangular spot under offset of laser beam 0.2 mm, (a) zone A, (b) zone B, (c) zone C, (d) zone D.

Fig. 11. Inuence of fracture location on tensile strength of joints.

narrow process window because interfacial reaction is sensitive for

the offset of laser beam. Vaidya et al. [18,19] reported that sheets
of AA6056 and Ti6Al4V were butt-joined by inserting the Tisheet into the proled Al-sheet and by melting the Al-alloy alone
using a split beam Nd: YAG laser. In order to improve spreadability
of liquid metal and nonhomogeneity of interfacial reaction, two
separate laser beam are required on both sides of the workpiece.
Compared with above methods, rectangular spot laser welding
brazing has relatively uniform interfacial reaction along the inter-

face, which means that this method can enhance controllability of

interfacial reaction, and expands usable range of the process
parameters. In addition, this method needs only relative simple
processing equipment.
3.3. Tensile strength and fracture behavior
The controlling of rectangular spot laser weldingbrazing on
interfacial reaction is benet to improve the mechanical properties

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S. Chen et al. / Materials and Design 32 (2011) 44084416

depending on the thickness of interfacial reaction layer of the joint.

Therefore, the statistical analysis was conducted for tensile
strength values of all specimens.
In general, the specimens exhibit four fracture types, namely in
partial interface, in the seam, in the interface and in the porosity.
Fig. 11 presents the inuence of fracture types on the average tensile strength of the joints. The average value of tensile strength broken in the seam is 278 MPa, up to 88% of Al base metals, which is
signicantly higher than others. In addition, the uctuation of tensile strength value broken in the seam (263  294 MPa) is lower
than that broken in partial interface (128  267 MPa) and in the
interface and porosity (111  258 MPa), which means that these
joints fractured in the seam have steady mechanical properties.
This is due to the fact that rectangular spot laser weldingbrazing
improves nonhomogeneity of interfacial reaction along the
interface.
It should be pointed out that interfacial reaction is still somewhat uneven along the interface in spite of interfacial reaction
nonhomogeneity can be improved by rectangular spot with relatively uniform energy distribution combined with V-shape groove
on parent metal. In the case of low heat input, there is insufcient
interfacial reaction at the end of joint, which means that the joining is possibly only mechanical occlusion. Thus, this zone is weak,
which induces the type of fracture in partial interface. Under conditions of high heat input, there is over interfacial reaction at the
interface, and excess intermetallic compounds are formed and a
mass of porosities appear in the seam, which induces the type of
fracture in the interface or porosity [17]. When the heat input is
appropriate in the range of wider usable process parameter, the
joints fracture in the seam and have the highest mechanical
properties.
4. Conclusions
According to investigations of interfacial reaction nonhomogeneity of Al/Ti joints by laser weldingbrazing process, conclusions
were summarized as follows:
(1) Rectangular spot laser weldingbrazing combined with Vshaped groove on parent metal can ensure that the interface
is parallel roughly to the isotherm of the temperature eld,
which decreases temperature gradient along the interface.
This has consumedly improved interfacial reaction
nonhomogeneity.
(2) Compared with circular spot mode with Gaussian energy
distribution, rectangular spot laser weldingbrazing with
relative uniform energy distribution can enhance the uniformity of interfacial reaction along the interface, and this
method exhibits wider appropriate process parameter
window.
(3) The average tensile strength of the joints broken in the seam
is 278 MPa, which is signicantly higher than that in partial
interface, in the interface or in the porosity. The uctuation
of tensile strength broken in the seam is lower than others,
which means that these joints fracture in the seam and have
steady mechanical properties.

Acknowledgments
The authors would like to thank State Key Laboratory of Welding of China, all of the work within which were conducted. They
also appreciate the nancial support from the National Natural Science Foundation of China (No. 51004009).

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