Hot cracking and porosity are the main two challenges of weld quality for remote laser welding of high strength aluminum alloy in automotive applications; Various surface cleaning methods have been studied and used for weld porosity reduction; The two main approaches for hot cracking reductions are: Increasing Si composition in weld pool to enhance the liquid backfill capability in the mushy zone; Reducing stress and strain induced by the thermal cycle of laser welding process; The current methods having been used to stress reduction for hot cracking reduction are: Joint: design (selection of flange width, penetration, etc.); Trailered heat source shape; Power distribution optimization via beam oscillation and shaping; Aluminum-welding friendly process parameters settings.
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