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However, laser welding of high-strength aluminum alloys at high welding speeds may result in the formation of transverse hot cracks in the weld seam, potentially causing component failure due to leakage. To determine strategies to avoid transverse hot cracks, the influence of the welding speed during full-penetration laser welding is analyzed both experimentally and theoretically using numerical simulations of the temperature field and the fluid flow. A metallographic analysis of the welded samples showed an increase in the number of transverse hot cracks with increasing welding speeds. The results revealed that a major mechanism for the formation of transverse hot cracks at high welding speeds is a significant reduction of the static pressure at the side of the melt pool, which impairs liquid feeding into the intergranular region. These findings provide fundamental knowledge for the development of optimization strategies to reduce the formation of transverse hot cracks at high welding speeds.","annote":"","author":[{"family":"Michel","given":"Johannes"},{"family":"Wagner","given":"Jonas"},{"family":"Holder","given":"Frauke"},{"family":"Zaiß","given":"Felix"},{"family":"Hagenlocher","given":"Christian"},{"family":"Graf","given":"Thomas"}],"citation-label":"Michel_2025_Mechanisms_Cracks","collection-editor":[],"collection-title":"","container-author":[],"container-title":"Optics & Laser Technology","documents":[],"edition":"","editor":[],"event-date":{"date-parts":[["2025","December"]],"literal":"2025"},"event-place":"","id":"a8db9c33dd141c0142c37aec16c3482cjmichel","interhash":"f0ab1e31d3b83b52a60c3373e0a9d2d9","intrahash":"a8db9c33dd141c0142c37aec16c3482c","issue":"","issued":{"date-parts":[["2025","December"]],"literal":"2025"},"keyword":"Aluminium FluidFlow HotCracking Laser Simulation Welding myown peer","misc":{"language":"English","issn":"0030-3992","doi":"10.1016/j.optlastec.2025.113898"},"note":"","number":"","page":"113898","page-first":"113898","publisher":"Elsevier BV","publisher-place":"","status":"","title":"Mechanisms of transverse hot crack formation during laser welding of high-strength aluminum alloys at high welding speeds","type":"article-journal","username":"jmichel","version":"","volume":"192"},"a8db9c33dd141c0142c37aec16c3482cifsw":{"DOI":"10.1016/j.optlastec.2025.113898","ISBN":"","ISSN":"0030-3992","URL":"http://dx.doi.org/10.1016/j.optlastec.2025.113898","abstract":"High-strength aluminum alloys provide favorable material properties for components in modern battery systems, such as battery trays used in electromobility applications. However, laser welding of high-strength aluminum alloys at high welding speeds may result in the formation of transverse hot cracks in the weld seam, potentially causing component failure due to leakage. To determine strategies to avoid transverse hot cracks, the influence of the welding speed during full-penetration laser welding is analyzed both experimentally and theoretically using numerical simulations of the temperature field and the fluid flow. A metallographic analysis of the welded samples showed an increase in the number of transverse hot cracks with increasing welding speeds. The results revealed that a major mechanism for the formation of transverse hot cracks at high welding speeds is a significant reduction of the static pressure at the side of the melt pool, which impairs liquid feeding into the intergranular region. 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These cracks are initiated as a result of thermal deformation, the decrease of the static pressure in the melt pool and the shrinkage during solidification. Particularly, this affects alloys of the 6000 series with elevated concentrations of the alloying elements silicon and magnesium. In [1], authors have demonstrated that applying external mechanical compressive stresses during welding reduces the formation of transverse hot cracks due to an increase of the static pressure in the melt pool. However, since such compressive stresses cannot always be applied externally, it would be desirable to induce these stresses within the sheet metal material. Against this background, near-surface embossing [2] was used in the present study to induce compressive residual stresses in sheet metals. Simulations were first carried out to examine the effects of varying the distances between the embossed patterns and the weld seam area to determine whether the compressive stresses affect the welding zone. Subsequently, several configurations of embossed sheets were produced, analyzed and welded. Finally, the resulting hot cracks were analyzed using metallographic sections and the results were compared with unembossed welded samples. The comparison of embossed and unembossed samples revealed the amount of residual compressive stresses and thus the formation of hot cracks can be reduced depending on the distance and design of the embossing pattern. This proves embossing to be a valid method for inducing compressive residual stresses into sheet metal and thus to reduce the formation of hot cracks during welding.","annote":"","author":[{"family":"Bachmann","given":"Maximilian"},{"family":"Riedmüller","given":"Kim Rouven"},{"family":"Michel","given":"Johannes"},{"family":"Hagenlocher","given":"Christian"},{"family":"Liewald","given":"Mathias"},{"family":"Graf","given":"Thomas"}],"citation-label":"BACHMANN_2025_presentation","collection-editor":[],"collection-title":"","container-author":[],"container-title":"","documents":[],"edition":"","editor":[],"event-date":{"date-parts":[["2025"]],"literal":"2025"},"event-place":"","id":"853b939fcd9667b6f42a0e7376415ec1ifsw","interhash":"e0e8f74c11b06f561263ecdee9ce9a6c","intrahash":"853b939fcd9667b6f42a0e7376415ec1","issue":"","issued":{"date-parts":[["2025"]],"literal":"2025"},"keyword":"myown ResidualStress Welding Embossing simulation HotCracking Aluminium","misc":{"eventtitle":"Conference on Material Forming ESAFORM 2025","venue":"Paestum, Italy","language":"English","collection":"ESAFORM 2025","eventdate":"7-9 May 2025"},"note":"","number":"","page":"","page-first":"","publisher":"","publisher-place":"","status":"","title":"Influence of near-surface embossing on the hot crack formation during laser beam welding of metal sheets from 6000 aluminum alloys","type":"speech","username":"ifsw","version":"","volume":""},"853b939fcd9667b6f42a0e7376415ec1jmichel":{"DOI":"","ISBN":"","ISSN":"","URL":"","abstract":"During laser beam welding of aluminum alloys, the formation of transverse hot cracks in the weld seam represents a critical issue that can substantially impair the mechanical strength and quality of welded joints. These cracks are initiated as a result of thermal deformation, the decrease of the static pressure in the melt pool and the shrinkage during solidification. Particularly, this affects alloys of the 6000 series with elevated concentrations of the alloying elements silicon and magnesium. In [1], authors have demonstrated that applying external mechanical compressive stresses during welding reduces the formation of transverse hot cracks due to an increase of the static pressure in the melt pool. However, since such compressive stresses cannot always be applied externally, it would be desirable to induce these stresses within the sheet metal material. Against this background, near-surface embossing [2] was used in the present study to induce compressive residual stresses in sheet metals. Simulations were first carried out to examine the effects of varying the distances between the embossed patterns and the weld seam area to determine whether the compressive stresses affect the welding zone. Subsequently, several configurations of embossed sheets were produced, analyzed and welded. Finally, the resulting hot cracks were analyzed using metallographic sections and the results were compared with unembossed welded samples. The comparison of embossed and unembossed samples revealed the amount of residual compressive stresses and thus the formation of hot cracks can be reduced depending on the distance and design of the embossing pattern. This proves embossing to be a valid method for inducing compressive residual stresses into sheet metal and thus to reduce the formation of hot cracks during welding.","annote":"","author":[{"family":"Bachmann","given":"Maximilian"},{"family":"Riedmüller","given":"Kim Rouven"},{"family":"Michel","given":"Johannes"},{"family":"Hagenlocher","given":"Christian"},{"family":"Liewald","given":"Mathias"},{"family":"Graf","given":"Thomas"}],"citation-label":"BACHMANN_2025_presentation","collection-editor":[],"collection-title":"","container-author":[],"container-title":"","documents":[],"edition":"","editor":[],"event-date":{"date-parts":[["2025"]],"literal":"2025"},"event-place":"","id":"853b939fcd9667b6f42a0e7376415ec1jmichel","interhash":"e0e8f74c11b06f561263ecdee9ce9a6c","intrahash":"853b939fcd9667b6f42a0e7376415ec1","issue":"","issued":{"date-parts":[["2025"]],"literal":"2025"},"keyword":"Aluminium Embossing HotCracking ResidualStress Welding myown simulation","misc":{"eventtitle":"Conference on Material Forming ESAFORM 2025","venue":"Paestum, Italy","language":"English","collection":"ESAFORM 2025","eventdate":"7-9 May 2025"},"note":"","number":"","page":"","page-first":"","publisher":"","publisher-place":"","status":"","title":"Influence of near-surface embossing on the hot crack formation during laser beam welding of metal sheets from 6000 aluminum alloys","type":"speech","username":"jmichel","version":"","volume":""},"e5a0d800dbe296854407a25da82b35d7jmichel":{"DOI":"10.21741/9781644903599-133","ISBN":"","ISSN":"2474-395X","URL":"http://dx.doi.org/10.21741/9781644903599-133","abstract":"During laser beam welding of aluminum alloys, the formation of transverse hot cracks\r\nin the weld seam represents a critical issue that can substantially impair the mechanical strength\r\nand quality of welded joints. These cracks are initiated as a result of thermal deformation, the\r\ndecrease of the static pressure in the melt pool and the shrinkage during solidification. Particularly,\r\nthis affects alloys of the 6000 series with elevated concentrations of the alloying elements silicon\r\nand magnesium. In [1], authors have demonstrated that applying external mechanical compressive\r\nstresses during welding reduces the formation of transverse hot cracks due to an increase of the\r\nstatic pressure in the melt pool. However, since such compressive stresses cannot always be\r\napplied externally, it would be desirable to induce these stresses within the sheet metal material.\r\nAgainst this background, near-surface embossing [2] was used in the present study to induce\r\ncompressive residual stresses in sheet metals. Simulations were first carried out to examine the\r\neffects of varying the distances between the embossed patterns and the weld seam area to\r\ndetermine whether the compressive stresses affect the welding zone. Subsequently, several\r\nconfigurations of embossed sheets were produced, analyzed and welded. Finally, the resulting hot\r\ncracks were analyzed using metallographic sections and the results were compared with\r\nunembossed welded samples. The comparison of embossed and unembossed samples revealed the\r\namount of residual compressive stresses and thus the formation of hot cracks can be reduced\r\ndepending on the distance and design of the embossing pattern. This proves embossing to be a\r\nvalid method for inducing compressive residual stresses into sheet metal and thus to reduce the\r\nformation of hot cracks during welding.","annote":"","author":[{"family":"Bachmann","given":"Maximilian"},{"family":"Riedmüller","given":"Kim Rouven"},{"family":"Michel","given":"Johannes"},{"family":"Hagenlocher","given":"Christian"},{"family":"Liewald","given":"Mathias"},{"family":"Graf","given":"Thomas"}],"citation-label":"BACHMANN_2025","collection-editor":[],"collection-title":"ESAFORM 2025","container-author":[],"container-title":"Material Forming: ESAFORM 2025","documents":[],"edition":"","editor":[],"event-date":{"date-parts":[["2025"]],"literal":"2025"},"event-place":"","id":"e5a0d800dbe296854407a25da82b35d7jmichel","interhash":"e0e8f74c11b06f561263ecdee9ce9a6c","intrahash":"e5a0d800dbe296854407a25da82b35d7","issue":"","issued":{"date-parts":[["2025"]],"literal":"2025"},"keyword":"Aluminium Embossing HotCracking ResidualStress Welding myown simulation","misc":{"venue":"Paestum, Italy","collection":"ESAFORM 2025","eventdate":"7-9 May 2025","eventtitle":"Conference on Material Forming ESAFORM 2025","issn":"2474-395X","doi":"10.21741/9781644903599-133"},"note":"","number":"","number-of-pages":"7","page":"1221–1228","page-first":"1221","publisher":"Materials Research Forum LLC","publisher-place":"","status":"","title":"Influence of near-surface embossing on the hot crack formation during laser beam welding of metal sheets from 6000 aluminum alloys","type":"paper-conference","username":"jmichel","version":"","volume":"54"},"e5a0d800dbe296854407a25da82b35d7ifsw":{"DOI":"10.21741/9781644903599-133","ISBN":"","ISSN":"2474-395X","URL":"http://dx.doi.org/10.21741/9781644903599-133","abstract":"During laser beam welding of aluminum alloys, the formation of transverse hot cracks\r\nin the weld seam represents a critical issue that can substantially impair the mechanical strength\r\nand quality of welded joints. These cracks are initiated as a result of thermal deformation, the\r\ndecrease of the static pressure in the melt pool and the shrinkage during solidification. Particularly,\r\nthis affects alloys of the 6000 series with elevated concentrations of the alloying elements silicon\r\nand magnesium. In [1], authors have demonstrated that applying external mechanical compressive\r\nstresses during welding reduces the formation of transverse hot cracks due to an increase of the\r\nstatic pressure in the melt pool. However, since such compressive stresses cannot always be\r\napplied externally, it would be desirable to induce these stresses within the sheet metal material.\r\nAgainst this background, near-surface embossing [2] was used in the present study to induce\r\ncompressive residual stresses in sheet metals. Simulations were first carried out to examine the\r\neffects of varying the distances between the embossed patterns and the weld seam area to\r\ndetermine whether the compressive stresses affect the welding zone. Subsequently, several\r\nconfigurations of embossed sheets were produced, analyzed and welded. Finally, the resulting hot\r\ncracks were analyzed using metallographic sections and the results were compared with\r\nunembossed welded samples. The comparison of embossed and unembossed samples revealed the\r\namount of residual compressive stresses and thus the formation of hot cracks can be reduced\r\ndepending on the distance and design of the embossing pattern. This proves embossing to be a\r\nvalid method for inducing compressive residual stresses into sheet metal and thus to reduce the\r\nformation of hot cracks during welding.","annote":"","author":[{"family":"Bachmann","given":"Maximilian"},{"family":"Riedmüller","given":"Kim Rouven"},{"family":"Michel","given":"Johannes"},{"family":"Hagenlocher","given":"Christian"},{"family":"Liewald","given":"Mathias"},{"family":"Graf","given":"Thomas"}],"citation-label":"BACHMANN_2025","collection-editor":[],"collection-title":"ESAFORM 2025","container-author":[],"container-title":"Material Forming: ESAFORM 2025","documents":[],"edition":"","editor":[],"event-date":{"date-parts":[["2025"]],"literal":"2025"},"event-place":"","id":"e5a0d800dbe296854407a25da82b35d7ifsw","interhash":"e0e8f74c11b06f561263ecdee9ce9a6c","intrahash":"e5a0d800dbe296854407a25da82b35d7","issue":"","issued":{"date-parts":[["2025"]],"literal":"2025"},"keyword":"myown ResidualStress Welding Embossing simulation HotCracking Aluminium","misc":{"venue":"Paestum, Italy","collection":"ESAFORM 2025","eventdate":"7-9 May 2025","eventtitle":"Conference on Material Forming ESAFORM 2025","issn":"2474-395X","doi":"10.21741/9781644903599-133"},"note":"","number":"","number-of-pages":"7","page":"1221–1228","page-first":"1221","publisher":"Materials Research Forum LLC","publisher-place":"","status":"","title":"Influence of near-surface embossing on the hot crack formation during laser beam welding of metal sheets from 6000 aluminum alloys","type":"paper-conference","username":"ifsw","version":"","volume":"54"},"b357d5772d11474e079011ef5a7b594cjmichel":{"DOI":"","ISBN":"","ISSN":"","URL":"","abstract":"High-strength aluminum alloys offer excellent weight-specific mechanical properties, making them an ideal choice for parts in electromobility applications like battery trays. However, their susceptibility to transverse hot cracking during laser welding at high welding velocities is challenging. This study investigates the mechanisms of transverse hot crack formation by means of numerical simulations of the temperature field and melt flow in the melt pool and validates the results with experiments. The results reveal a critical zone at the side of the melt pool which is characterized by a high static pressure drop at the liquidus isotherm as a result of high melt flow velocities and cooling rates, which affect the intergranular melt flow during solidification. The study provides valuable findings, which enable the optimization of high-speed laser welding of aluminum alloys, to avoid the formation of transverse hot cracks.","annote":"","author":[{"family":"Michel","given":"Johannes"},{"family":"Wagner","given":"Jonas"},{"family":"Holder","given":"Frauke"},{"family":"Zaiß","given":"Felix"},{"family":"Haas","given":"Michael"},{"family":"Hagenlocher","given":"Christian"},{"family":"Graf","given":"Thomas"}],"citation-label":"michel2025transversecracks","collection-editor":[],"collection-title":"","container-author":[],"container-title":"","documents":[],"edition":"","editor":[],"event-date":{"date-parts":[["2025"]],"literal":"2025"},"event-place":"","id":"b357d5772d11474e079011ef5a7b594cjmichel","interhash":"3bd32eab7941897d45cf2e73a769eeb4","intrahash":"b357d5772d11474e079011ef5a7b594c","issue":"","issued":{"date-parts":[["2025"]],"literal":"2025"},"keyword":"Aluminium Cracking MacroMaterialProcessing Simulation Welding myown","misc":{"eventtitle":"Lasers in Manufacturing Conference  LiM 2025","venue":"Munich, Germany","language":"English","eventdate":"23 - 26 June 2025"},"note":"","number":"","page":"","page-first":"","publisher":"","publisher-place":"","status":"","title":"Transverse hot cracking in high-speed laser welding of high-strength aluminum alloys","type":"speech","username":"jmichel","version":"","volume":""},"b357d5772d11474e079011ef5a7b594cifsw":{"DOI":"","ISBN":"","ISSN":"","URL":"","abstract":"High-strength aluminum alloys offer excellent weight-specific mechanical properties, making them an ideal choice for parts in electromobility applications like battery trays. However, their susceptibility to transverse hot cracking during laser welding at high welding velocities is challenging. This study investigates the mechanisms of transverse hot crack formation by means of numerical simulations of the temperature field and melt flow in the melt pool and validates the results with experiments. The results reveal a critical zone at the side of the melt pool which is characterized by a high static pressure drop at the liquidus isotherm as a result of high melt flow velocities and cooling rates, which affect the intergranular melt flow during solidification. The study provides valuable findings, which enable the optimization of high-speed laser welding of aluminum alloys, to avoid the formation of transverse hot cracks.","annote":"","author":[{"family":"Michel","given":"Johannes"},{"family":"Wagner","given":"Jonas"},{"family":"Holder","given":"Frauke"},{"family":"Zaiß","given":"Felix"},{"family":"Haas","given":"Michael"},{"family":"Hagenlocher","given":"Christian"},{"family":"Graf","given":"Thomas"}],"citation-label":"michel2025transversecracks","collection-editor":[],"collection-title":"","container-author":[],"container-title":"","documents":[],"edition":"","editor":[],"event-date":{"date-parts":[["2025"]],"literal":"2025"},"event-place":"","id":"b357d5772d11474e079011ef5a7b594cifsw","interhash":"3bd32eab7941897d45cf2e73a769eeb4","intrahash":"b357d5772d11474e079011ef5a7b594c","issue":"","issued":{"date-parts":[["2025"]],"literal":"2025"},"keyword":"myown Welding Simulation Cracking MacroMaterialProcessing Aluminium","misc":{"eventtitle":"Lasers in Manufacturing Conference  LiM 2025","venue":"Munich, Germany","language":"English","eventdate":"23 - 26 June 2025"},"note":"","number":"","page":"","page-first":"","publisher":"","publisher-place":"","status":"","title":"Transverse hot cracking in high-speed laser welding of high-strength aluminum alloys","type":"speech","username":"ifsw","version":"","volume":""},"2a6819248e2bec9f5501fe6a7ed724f4annettegugel":{"DOI":"10.3390/en18061544","ISBN":"","ISSN":"","URL":"","abstract":"","annote":"","author":[{"family":"Fischer","given":"Nelly-Lee"},{"family":"Eschmann","given":"L."},{"family":"Rudion","given":"Krzysztof"}],"citation-label":"nlfischerleschmann2025regionalization","collection-editor":[],"collection-title":"","container-author":[],"container-title":"Energies","documents":[],"edition":"","editor":[],"event-date":{"date-parts":[["2025"]],"literal":"2025"},"event-place":"","id":"2a6819248e2bec9f5501fe6a7ed724f4annettegugel","interhash":"9db81b05e4245d97297f51e5d150705f","intrahash":"2a6819248e2bec9f5501fe6a7ed724f4","issue":"1544","issued":{"date-parts":[["2025"]],"literal":"2025"},"keyword":"Agent-Based Cars Charging Demand Electric Grid Level Location-Dependent Mobility Passenger Regionalization Simulation Square Using an at of the","misc":{"doi":"10.3390/en18061544"},"note":"","number":"1544","page":"","page-first":"","publisher":"","publisher-place":"","status":"","title":"Regionalization of the Location-Dependent Charging Demand of Electric Passenger Cars at the Grid Square Level Using an Agent-Based Mobility Simulation","type":"article-journal","username":"annettegugel","version":"","volume":"18"}}