High-strength and crack-free welding of 2024 aluminium alloy via Zr-core-Al-shell wire

The 2000 series aluminium alloys are qualified for widespread use in lightweight structures, but solidification cracking during fusion welding has been a long-standing issue. Here, we create a zirconium (Zr)-core-aluminium (Al)-shell wire (ZCASW) and employ the oscillating laser-arc hybrid welding technique to control solidification during welding, and ultimately achieve reliable and crack-free welding of 2024 aluminium alloy. We select Zr wires with an ideal lattice match to Al based on crystallographic information and wind them by the Al wires with similar chemical components to the parent material. Crack-free, equiaxed (where the length, width and height of the grains are roughly equal), fine-grained microstructures are acquired, thereby considerably increasing the tensile strength over that of conventional fusion welding joints, and even comparable to that of friction stir welding joints. This work has important engineering application value in welding of high-strength aluminum alloys.