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A 14 kW CO2 laser and reflective optics were utilized to produce specimens for obtaining typical joint properties associated with laser beam welds of automotive aluminum alloys. The results of static and dynamic testing of these welds indicated that the laser beam welding process is capable of producing high quality welds. In all cases, the measured yield strength of butt welds exceeded the minimum yield strength of base material specified for these alloys. Post weld aging of the heat treatable alloys resulted in a moderate increase in strength of butt welds but virtually no effect on joint strength of lap welds. Butt welds produced with filler metal additions on the non-heat treatable alloys exhibited improved joint strength in comparison to welds produced autogenously. Butt welds displayed, as expected, displayed significantly higher fatigue endurance when compared to lap welds.

The use of aluminum is rapidly gaining acceptance for structural applications in the automotive industry. While laser beam welding offers many advantages for joining of aluminum alloys, it also possess certain inherent characteristics that differentiates laser beam welding of aluminum alloys from ferrous materials. These characteristics include aluminum's high reflectivity, large differences in vapor pressure between aluminum and many of its alloying constituents, and relatively low surface tension and viscosity in the molten state. This paper addresses process requirements for effective laser beam welding of aluminum alloys designed primarily for automotive applications and characterization of welded joints commonly used in the automotive industry.