Abstract:
The Digital Image Correlation (DIC) method was employed for rapid, non-destructive measurement of residual stress of 6061aluminum alloy laser-MIG hybrid welded joints. In the process of the measurement of residual stress using the DIC method, dense grid markers were drawn on the surface of the test piece with a pencil, and the zero-mean normalized cross-correlation function insensitive to light intensity variation was selected to achieve precise matching of measurement points before and after hybrid welding. In the heat-affected zone and base metal zone of aluminum alloy laser-MIG hybrid welded joints, DIC method obtained results consistent with those measured by X-ray diffraction method. Moreover, the deviation between the results measured by both methods decreased with increasing distance from the weld center line. The residual stress distribution and morphology of the welded joints of 8 mm 6061 aluminum alloy plates under different hybrid heat source energy ratios were comprehensively analyzed, and the laser-MIG hybrid welding parameters were optimized. The results demonstrate that the maximum value (peak) of residual stress measured by DIC method increases with the increase of laser power proportion in the total energy input. When selecting welding parameters for MIG arc to laser energy ratios of 1.1, 1.0, and 0.9, the measured peak magnitude of longitudinal stresses in the joint were 188 MPa, 195 MPa, and 199 MPa respectively, while the measured peak magnitude of transverse residual stress were 84 MPa, 94 MPa, and 99 MPa respectively. This ensures no excessive stress peaks will occur, and the joint has a small form factor, thus achieving satisfactory welding formation.