Optics & Laser Technology 141 (2021) 107121

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Optics and Laser Technology

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Comparative investigation between fiber laser and disk laser:

Microstructure feature of 2219 aluminum alloy welded joint using different
laser power and welding speed
Shi He a, Liyuan Liu b, Yanqiu Zhao a, Yue Kang a, Feifan Wang b, Xiaohong Zhan a, *
a
College of Materials Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing 211106, China
b
Beijing Institute of Astronautical Systems Engineering, China Academy of Launch Vehicle Technology, Beijing 100076, China

A R T I C L E I N F O A B S T R A C T

Keywords: In this investigation, the 2219 aluminum alloy sheets with a thickness of 1.5 mm are welded by different types of
Fiber laser lasers. By analyzing the macro-morphology and microstructure of the weld obtained by two different laser
Disc laser welding methods, the characteristics of welding aluminum alloy by using these different lasers are studied. The
Aluminum alloy
results indicate that under the gravity of molten pool and different laser power densities, the weld seams (WS)
Weld morphology
welded by fiber laser and disc laser are in X-shape and Y-shape respectively. Besides, under the influence of
Grain size
Marangoni convection, the equiaxed fine grains of the weld are brought into the middle part, forming a small and
regular equiaxed crystal zone (EQZ). It is found that the widths of the WS and the heat-affected zone (HAZ)
obtained by fiber laser are both wider than those welded by disc laser. The grain size of columnar dendrites and
equiaxed dendrites in the WS welded by fiber laser is coarser than that welded by disc laser. The tensile strengths
of disc-laser-welded joints are also higher. In short, disc lasers are more suitable for high-power laser welding
aluminum alloys.

1. Introduction
Aluminum alloys are widely used in various fields because of such
advantages as low density, high strength, high hardness and so on.
Under the condition of meeting the strength requirements, aluminum
alloys can not only reduce the weight of aerospace equipment, but also
reduce fuel consumption and cost. 2219 aluminum alloy is becoming
more and more critical in the aerospace field due to its high specific
strength, high specific stiffness, corrosion resistance and good weld­
ability [1,2]. At present, the experimental studies of aluminum alloy
welding methods have been conducted by numerous scholars, such as
tungsten inert gas welding, friction stir welding, electron beam welding,
etc. Relatively reliable conclusions have been drawn through the com­
parison of the influences by using different welding methods on the weld
structure and properties of aluminum alloy [3,4,5]. Heat is transfered
significant quickly in aluminum alloy due to its excellent thermal con­
ductivity. Therefore, the advent of high-power lasers with such advan­
tages as high efficiency gradually attracts scholars’ attention to laser
welding aluminum alloy [6,7].
In this study, two different type of lasers are used to weld 2219
aluminum alloy for the purpose of studying the welding performance.
The principle that laser generated by fiber and disc laser is quite similar
[8,9]. Nevertheless, the differences in gain medium and working circuit
between fiber and disc laser exist inevitably. Fiber laser refers to the
laser with glass fiber doped with rare earth elements as the gain medium
[10]. The gain medium of the disc laser is Yb:YAG crystal [11]. Addi­
tionally, the energy transfer between fiber and disc laser is equivalent
when the laser power is low, but disc laser can produce deeper pene­
tration at higher power conditions [12]. Therefore, it will have a specific
influence on the welding joints when using fiber and disc laser for
aluminum alloy welding tests.
In the field of material processing, especially in aluminum alloy
welding, the application of laser beam is becoming more and more
frequently. Zuo [13] has conducted laser beam welding (LBW) experi­
ments on various aluminum alloys with CO2 laser in early 1993. His
study, the influence of welding speed on welding pores and cracks, has
proved the feasibility of laser welding. In recent years, a large number of
scholars have carried out welding tests on 2219 aluminum alloy by using
different lasers. The conclusion that lasers have a great influence on joint
performance has been found. Welding tests of 2219 aluminum alloy with

* Corresponding author.
E-mail address: xiaohongzhan_nuaa@126.com (X. Zhan).

https://doi.org/10.1016/j.optlastec.2021.107121
Received 15 November 2020; Received in revised form 4 March 2021; Accepted 4 April 2021
Available online 17 April 2021
0030-3992/© 2021 Elsevier Ltd. All rights reserved.
S. He et al. Optics and Laser Technology 141 (2021) 107121

fiber laser have been realized by Zhu [14]. The purpose is to study the
strengthening mechanism under the cooperative effects of solid
solution-double aging treatment and pulsed electromagnetic forming.
Olatunji [15] has studied the effect of beam’s travel-path and penetra­
tion depths on the mechanical properties, microstructure and fracture
modes in fiber laser welded 2219 aluminum alloy lap joints. In addition,
the results of aluminum alloy welding by disc laser have also been
studied. Abioye [16] has used disc laser to weld AA 5052-H32. The
consequence that the interaction between welding speed and focal po­
sition has a significant effect on weld penetration depth has been drawn.
The ad-hoc trial has been completed by Alfieria [17] who uses disk laser
to weld AA 2024 aluminum alloy, which shows that the evaporation of
magnesium leads to the formation of macroscopic pores and the
reduction of strength.
However, the study that the effect on the forming of aluminum alloy
WS by using different lasers is in a minor quantity. Therefore, the
welding experiments of 2219 aluminum alloy sheet butt structure are
carried out by using fiber laser and disc laser under different welding
parameters, respectively. The macroscopic morphology and micro­
structure of the joints welded by fiber laser and disc laser are detected
and discussed.

2. Experimental procedure

2.1. Experimental materials

Fig. 1. (a) The schematic diagram of LBW, (b) the morphology of molten pool
The 2219 aluminum alloy is used as the base metal (BM). The thin along the welding direction.
plate butt structure is adopted in this study as well. The size of the plates
is 100 × 50 × 1.5 mm3 (length × width × thickness). There is no groove
and the defocusing is 0 mm. The composition of 2219 aluminum alloy is
shown in Table 1. The schematic diagram of LBW is depicted in Fig. 1.
The laser and the plate are perpendicular to each other. The shielding
gas which is blown by side axis moves in a straight line with the laser, so
that it can protect the welding pool at any time. The shielding gas is
99.99% Argon with flow rate of 15 L⋅min− 1 during the whole welding
process. When laser power density reaches 106 W⋅cm− 2, part of metal
surface is quickly heated and vaporized, creating a small hole in the
molten pool which called the keyhole. Keyhole formation is a significant
feature of high-power laser welding [18].

2.2. Experimental devices

The experimental equipment, which is demonstrated in Fig. 2, con­

sists of YLS-6000 fiber laser, TruDisk-12003 disc laser, KR60HA robot
and weld fixture. Subsequently, uniaxial tensile tests are conducted on
the universal tensile testing machine, the size of tensile specimens is
shown in the Fig. 3.
The basic parameters of the two lasers are compared in Table 2. It has
been found that the laser beam quality which judged by M2 affects the
welding results [19,20]. The larger the value of M2 , the weaker the beam
quality. Under the premise of the same laser beam, the better the beam
Fig. 2. (a) YLS-6000-ECO fiber laser, (b) TruDisk-12003 disc laser, (c) KR60HA
quality, the smaller the laser focus, the higher the power density of the robot, (d) welding fixture equipment.
focus. The formula for M2 is as follows:
Bpp Therefore, the difference of beam quality and power density between
M2 = (1)
λ⋅π fiber laser and disc laser will affect the welding thermal process.
Addintionally, in order to ensure the accuracy of the experiments, the
In formula (1), M2 is the beam quality factor, Bpp is the beam
laser heads have used the same parameters, such as fiber diameter of
parameter product, λ is the laser wavelength. According to formula (1),
100 μm, focus length of 200 mm.
the M2 of fiber laser and disc laser can be calculated respectively.

Table 1
The chemical composition of 2219 aluminum alloy (wt.%).
Composition Cu Mn Ti Zr V Mg Zn Fe Si Al

Wt.% 5.8–6.8 0.2–0.4 0.02–0.1 0.1–0.25 0.05–0.15 0.02 0.1 0.3 0.2 Bal.

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S. He et al. Optics and Laser Technology 141 (2021) 107121

Fig. 3. Size of tensile specimens.

metallographic microscope in this paper.

Table 2
The grain size of the WS usually affects the joints performance so
Welding parameters of two different kinds lasers.
much that the grain sizes of columnar dendrite and equiaxed dendrite
Fiber laser Disc laser are measured in this paper. However, the intersection point method is
Maximum power (kW) 6 12 used to measure the grain size of the columnar dendrite zone while the
Energy efficiency (%) 25 15 area method is used to measure the grain size of equiaxed dendrite zone.
BPP 4.5 12 zl and zs are used to represent the grain size of columnar dendrites and
Size (m2) 1 4
Wavelength (nm) 1070 1030
equiaxed dendrites respectively [22,23]. The following formula could be
used to calculate them.
n
2.3. Experimental parameters zl = (3)
l

In this study, 6 groups of laser-welding experiments with different zs =

parameters are designed. The butt joint structures welded by fiber laser
and disc laser at different laser power and welding speed are compared.
The welding parameters of LBW are shown in Table 3. Additionally, the
welding linear energy [21], which represents the amount of energy
acting on per unit length during welding, plays an important role in weld
formation. The calculation formula is as follows:
J = P/V (2)
n
(4)
s
In formula (3) and (4), n is the number of grains in the specified
length and area which is measured by counting. l is the length of the
standard line. s is the area of the selected region. In short, the larger the
values of zl and zs , the smaller the grain size can be obtained.
3. Results and discussion

In formula (2), P is laser power and V is welding speed. 3.1. Macroscopic morphology analysis of weld seam

The WS macroscopic morphologies of 6 samples are selected to make

2.4. Method of grain measurement a comparison in this paper. In addition, the upper, middle and lower
width of the WS are measured for comparison as well, as shown in Fig. 4.
The macroscopic morphology of WS is detected in this study. The WS From the pictures, it is concluded that all WS have been thoroughly
widths of the upper, middle and lower part are measured and compared
welded. Slight sag has been found. This is due to the influence of the
firstly. Then the overall width of the WS is analyzed. molten pool gravity during the welding process, which causes the
It is well known that the HAZ is the unmelted part of the BM, which is
unsolidified molten metal to sag slightly, the molten pool is elongated
the weakest part. Because it is affected by the thermal cycle of welding vertically. Synchronously, this is the reason why the upper width of all
process, the grain size of this area is often large. The HAZ widths have a
WS is broader, while the middle is narrower.
significant influence on the performance of the joint. The HAZ widths of According to the formula (1), we can calculate theM2 of fiber laser
the upper, middle and lower joints are measured by a MR5000
and disc laser respectively, which are 1.34 and 3.71. Therefore, the
beam quality of fiber laser is better than that of disc laser, the fiber laser
Table 3 owns a higher power density than disc laser. In this case, under the same
2219 aluminum alloy LBW parameters. heating time, the fiber laser can produce more heating energy. When
Laser power Welding speed Welding line energy using fiber laser, the vaporization time of workpiece surface is shorter.
(W) (m⋅min− 1) (J⋅mm− 1) The inner layer of metal melts more, resulting in the broader weld. This
Fiber Case 2400 5 28.8 is consistent with the experimental results. As shown in Fig. 5.
laser 1 As shown in Fig. 4, the shape of WS obtained by fiber laser welding
Case 2600 5 31.2
(FLW) is mostly X-type while that of disc laser welding (DLW) is mostly
2
Case 2600 6 26
Y-type. Under the action of gravity, the molten metal flows downward
3 more, then the X-type weld is formed. While the DLW in the same
heating time produced less energy and the vaporization time of the
Disc Case 2400 5 28.8
laser 4 workpiece surface is more prolonged, causing the inner layer of metal
Case 2600 5 31.2 melting less and the welds getting narrower. Under the effect of gravity,
5 the molten metal flows downward less, then the Y-type weld is formed.
Case 2600 6 26 By comparing the weld width of each position in the Fig. 4, it can be
6

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S. He et al.
Fig. 4. Weld morphology (a-c) Welds obtained by FLW; (d-f) Welds obtained by DLW.
Fig. 5. Histogram of the average weld width.
found that basically all positions meet the requirement that the weld
width increases with the increase of laser power and decreases with the
welding speed increasing. In Fig. 5, the average width of the entire WS is
Fig. 6. (a) Schematic diagram of selected weld area; (b), (d), (f) Welds obtained by FLW; (c), (e), (g) Welds obtained by DLW.
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Optics and Laser Technology 141 (2021) 107121
measured. It can be concluded that the WS obtained by FLW are 0.087
mm broader than those obtained by DLW. However, whether it is fiber
laser or disc laser, the width of WS obtained at 2600 W, 5 m⋅min− 1 in this
paper is the widest, which can be explained by the maximum laser line
energy under this welding parameter.
3.2. Shape analysis of welds at different positions
In the upper location at the joints obtained by FLW and DLW, the
width of the HAZ is measured at the same distance. As shown in Fig. 6
(a), a measuring point is set every D(D = 60 μm), a total of 5 positions
are measured. From Fig. 6(b) to (g), there are fine equiaxed zone (EQZ)
in the welds. However, in the welding of disc laser, equiaxial grains can
be obtained only when the line energy is appropriate. Appropriate
welding line energy can make the weld get more regular organization
area. The shape of the HAZ is very regular and well-defined. According
to the distribution of Marangoni convection in the upper part of the
molten pool, as shown in Fig. 12, Marangoni convection brings the
heterogeneous point near the fusion line, where the metal nucleates and
grows as the temperature drops. Since the temperature gradient from the
fusion line to the center of the weld is the largest, the crystal grains grow
toward the center of the weld, forming columnar dendrites [24].
The measurement result is shown in Fig. 9 (a). The greater the
S. He et al.
welding line energy, the wider the welding HAZ. No matter which part it
is, the widest WS can be obtained at the laser power of 2600 W and the
welding speed of 5 m⋅min− 1, at which the maximum welding line energy
reaches 31.2 J⋅mm− 1. Consequently, the maximum HAZ width can be
formed under this welding parameter.
As shown in Fig. 7(a), the HAZ widths of 5 positions in the selected
area are measured, with interval of D for each position. From Fig. 7(b) to
(g), the conclusion can be gained that the areas of EQZ are not very
regular. When the welding line energy is large, the aera of EQZ in the
weld is small. Under the influence of the Marangoni convection in the
middle of the molten pool, shown in the Fig. 12, the hetro-particl are
distributed along the Marangoni convection. As the temperature drops,
equiaxed grains begin to nucleate and grow here. When the welding line
energy is at its maximum, there is almost no EQZ in the middle aera of
the WS. At this time, there are more areas melted in the molten pool but
the flow rate is the smallest, which causes the nucleated grains to grow
up and cannot form EQZ. As the welding speed increases, the cooling
rate of the molten pool also increases, so that the equiaxed grains after
nucleation grow to a certain size and stop growing due to contact,
forming EQZ.
By measuring the width of the HAZ in this area, as shown in the Fig. 9
(b), it is concluded that the HAZ of fiber laser welding is wider than that
of the disc laser. When the welding line energy is maximum, both the
FLW and DLW have obtained the maximum width of the HAZ.
It is also measured and analyzed at the bottom of the molten pool
according to the previous method. From Fig. 8(b) to (g), when the
welding line energy is large or small, there is almost no EQZ, but when it
is moderate, the EQZ is particularly obvious. The distribution of Mar­
angoni convection in the bottom area of the molten pool severely affects
the distribution of EQZ. Under ideal conditions, the grain distribution
will follow the way shown in Fig. 12(b). However, under actual condi­
tions, the force of Marangoni convection at the bottom of the molten
pool is relatively small, and the hetro-particl cannot be completely
brought into the bottom of the molten pool. Therefore, at the bottom of
the weld pool, nucleation occurs at the edge of the weld and grows to­
ward the center of the weld, forming columnar dendrites.
Similarly, the width of the HAZ at the bottom of the weld can be
clearly obtained from Fig. 9(c). From the data rules in the figure, a
conclusion consistent with the upper and middle parts of the weld can be
drawn.
The HAZ widths of the whole joint are compared in Fig. 9. The width
of the HAZ on the upper, middle, lower parts and the average width of
Fig. 7. (a) Schematic diagram of selected weld area; (b), (d), (f) Welds obtained by FLW; (c), (e), (g) Welds obtained by DLW.
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Optics and Laser Technology 141 (2021) 107121
the joint are shown in Fig. 9. Although it is concluded that the beam
quality of fiber laser is better than that of disc laser, the disc laser has
more advantages for high-power laser welding. That is why the width of
the HAZ obtained by DLW is narrower than that of FLW.
3.3. Analysis of grain size in different grain regions
The grain size of WS greatly affects the quality of the joint. The
smaller grains have larger inter contact area, which leads to higher yield
strength. Thus, the smaller grains in the weld seam have higher me­
chanical properties. In this section, the grain sizes of columnar dendrite
zone and equiaxed dendrite zone of WS are measured. The selected area
is shown in Fig. 10(a). The area at the distance X (X = 100 μm) from the
fusion line is the columnar dendrite zone, where the grain size is
measured by the intersection point method. Within the specified length
range, the larger the value of zl , the smaller the grains. By comparing the
value of zl in Fig. 10(h), it is concluded that the grain of columnar
dendrite obtained by using FLW is larger than that obtained by using
DLW. This shows that the focus power density of fiber laser is much
higher, which produces more energy. At the same welding speed, the
molten pool is slower to cool down, causing the grain growing larger. It
is also found that increasing the laser power will make the grain bigger
and increasing the welding speed will make the grain smaller, whether it
is fiber laser or disc laser. Laser welding line energy can be obtained with
larger laser power and smaller welding speed, under this condition the
grains getting also larger.
Affected by the Marangoni convection as shown in Fig. 12(a), the
crystal grains begin to nucleate and grow at the edge of the weld. Since
the temperature gradient toward the center of the weld is the largest
here, the crystal grains grow toward the center of the weld. The fault
structure appears in Fig. 10(g), specifically because the Marangoni
convection near the edge of the weld in the lower part makes the grains
nucleate and grow. However, the Marangoni convection in the middle
also has nucleation and growth. When the former grains grow to reach
the latter grains, they stop growing.
According to the distribution of Marangoni convection in the center
of the weld, it can be concluded that at the center of the weld, nucleation
can occur at various positions. The grains grow in all directions because
the temperature gradient in the center of the weld is relatively uniform,
forming equiaxed dendrite grains. As shown in Fig. 11, the grain size of
equiaxed dendrite in the center of the WS is measured by zs , which in­
dicates the grain size by measuring the number of grains in a specified
S. He et al. Optics and Laser Technology 141 (2021) 107121

Fig. 8. (a) Schematic diagram of selected weld area; (b), (d), (f) Welds obtained by FLW; (c), (e), (g) Welds obtained by DLW.

Fig. 9. (a) The upper average width of joint HAZ; (b) The middle average width of joint HAZ; (c) The lower average width of joint HAZ; (d) The total average width
of joint HAZ.

area. In Fig. 11(a), it is demonstrated that the location of the selected
region, which is 0.01 mm2 (0.1 mm × 0.1 mm). The grain size of each
case is shown in Fig. 11(h). It can be concluded that under the welding
parameters used in this study, the equiaxed dendrite i n the center of the
WS obtained by FLW is larger than that of DLW.
The schematic diagram of grain distribution is shown in Fig. 12(b).
The value of the temperature gradient will go down while the value of
the crystal growth rate will go up, that is why it is easy to form columnar
crystals at the edges of WS and equiaxed crystals at the center of WS.
Under actual circumstances, the shape of each zone in the joint is not

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S. He et al. Optics and Laser Technology 141 (2021) 107121

Fig. 10. (a) Schematic diagram of selected weld area; (b), (d), (f) Welds obtained by FLW; (c), (e), (g) Welds obtained by DLW; (h) The grain size of columnar
dendrites in the selected region.

Fig. 11. (a) Schematic diagram of selected weld area, (b), (d), (f) Welds obtained by FLW; (c), (e), (g) Welds obtained by DLW; (h) The grain size of equiaxed
dendrites in the selected region.

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S. He et al. Optics and Laser Technology 141 (2021) 107121

always regular. From the experimental results, it can be found that there
are still many EQZ in the weld.
As shown in Fig. 12, irregular shape of EQZ can be easily detected,
which has a bifurcation mostly. The irregularity of these regions can
reflect the anomaly of grain growth, the reason can be attributed to that
the number and distribution of heterogeneous nucleation points in
different areas of WS edge are different due to laser thermal action and
the influence of Marangoni convection in the molten pool. Moreover,
because of the convection of molten pool, part of nucleation points in the
upper and middle part of the WS will be brought into the molten pool.
On this basis, nucleation will grow up to form an equiaxed crystal belt
extending to the inner part of the WS. There are two conditions for EQZ
nucleation, one is that high melting point compounds are required as the
core of heterogeneous nucleation, the other is proper subcooling. The
weld edge can meet these two conditions at the same time, thus the EQZ
can be formed [25]. Just as in Fig. 7(c), part of the nucleus in the EQZ is
brought into the molten pool, resulting in its shape becoming bifurcated
from the middle and forming two parts after the nucleus grows. This is
the ideal state. While others may have different shapes of the EQZ due to
different flow directions and velocities in the weld pool and different Fig. 13. . Typical tensile strength-displacement curves of base metal, fiber-
environmental resistance of a grain growth. laser-welded joints, disc-laser-welded joints.

3.4. Analysis of tensile strength for different joints

The tensile strength-displacement curves are shown in Fig. 13. In the

process of tensile test, the yield stage of the base material appears
obviously. The tensile strength of the base material is up to 347 MPa.
However, there is no obvious yield stage in the tensile curve of fiber laser
welded joints, which indicates that the fracture mode may be brittle
fracture. In the weld seam of fiber laser welding, due to its wide weld
width, irregular grain structure and large grain size, the tensile strength
of the joint is only 186 MPa. Moreover, the fracture position of the weld
is shown in Fig. 14(a), near the center of the weld. A short period of yield
stage appears in the tensile curve of the joints welded by disc laser. Due
to smaller weld width, more regular grain structure and better grain size,
the joint has higher tensile strength, reaches 263 MPa. The fracture
position is as close to the weld center as the fiber laser joint. The fracture
surfaces of the BM, joints of FLW and joints of DLW are shown in Fig. 15.
A large number of dimples appear across the surface of the fracture,
which characterizes the ductile fracture mode of BM, as shown in Fig. 15
(a) and (b). There are not only dimples on the fracture surface of fiber-
laser-welded joints, but also a few features of quasi-cleavage fractures.
Therefore, the tensile strength of the joint is low. However, there are also
a large number of dimples in the fracture morphology of disc-laser-
welded joints. The fracture mode is the same ductile fracture of BM
and its tensile strength is high.

4. Conclusions

In this paper, the macroscopic morphology and microstructure of

2219 aluminum alloy butt joints welded by fiber and disc laser are
studied under different welding parameters. The following conclusions
can be drawn:

(1) Under the action of molten pool gravity and laser power density,
the WS of FLW is in X-shape, while that of DLW is in Y-shape.
Among the welding parameters selected in this paper, the wider
WS and larger grains are obtained when the welding speed de­
creases or the laser power increases.
(2) The widths of WS and HAZ welded by fiber laser are wider than
disc laser under the same welding parameter, the values of zl
andzs obtained by fiber laser are smaller than that welded by disc
laser, which shows that under the same welding parameters, fiber
lasers provide more heat than disk lasers.
Fig. 12. (a) Distribution of Marangoni convection in the molten pool, (b)
Schematic diagram of joint grain growth.

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S. He et al.
Fig. 14. Fracture location of different laser welded joint: (a) fracture section of FLW; (b) fracture section of DLW.
Fig. 15. Fracture surfaces of (a)–(b) base metal, (c)–(d) joints of FLW, (e)–(f)
joints of DLW.
(3) Under the influence of Marangoni convection, the structure in the
weld is not completely regular, in which EQZ appears at the edge
of the weld. The columnar dendrites at the bottom of the weld
obtain a fault structure.
(4) In the experimental results of this paper, the narrower fusion
zone, HAZ and fine grain of 2219 aluminm alloy are obtained by
disk laser welding, the tensile strength of the joint is corre­
spondingly higher, indicating that the disc laser is more suitable
for high-power aluminum alloy welding.
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Optics and Laser Technology 141 (2021) 107121
Declaration of Competing Interest
The authors declare that they have no known competing financial
interests or personal relationships that could have appeared to influence
the work reported in this paper.
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