New progress in laser welding of dissimilar materials in key engine parts

As a critical component in diesel engines, the turbocharger plays a vital role in enhancing engine performance and efficiency. The quality of welding between dissimilar materials significantly affects the overall reliability and durability of the turbocharger. Recently, the Joint Laboratory of Engine Science and Engineering at the Institute of Mechanics, Chinese Academy of Sciences, has achieved remarkable progress in laser welding of dissimilar materials used in turbochargers. This new process not only meets the demanding requirements for high-strength welds but also greatly improves welding efficiency, offering crucial technical support for advancing diesel engine performance. In turbochargers, turbine blades are typically made from nickel-based cast superalloy K418, while vortex rods are fabricated from 42CrMo alloy steel, a medium-tempered quenched and tempered steel. The laboratory conducted an in-depth study on the laser welding process for these two different materials. By analyzing the mechanism behind hot cracking, they developed an effective method to prevent such defects. Through precise control of the laser's energy distribution in both time and space, they successfully addressed issues like partial melting and incomplete fusion caused by the differing thermophysical properties of the materials. The results show that the optimized welding procedure ensures that the tensile strength of the weld exceeds that of the base metal, making it a promising solution for high-performance turbocharger manufacturing.

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