This paper conducts a numerical simulation of the laser welding process for 6056 aluminum alloy stringers and skin T-joints using Simufact Welding. Initially, the accuracy of the finite element simulation is validated, followed by an exploration of the impact of bilateral asynchronous and bilateral synchronous laser welding on molten pool stability. Process parameters, including laser power, welding speed, fixture clamping force, and preheat temperature, are optimized through orthogonal testing. Furthermore, the influence of welding sequences on post-weld equivalent stress and deformation in three stringers’ T-joints is analyzed. The numerical simulation results indicate that the stability of the molten pool is superior in bilateral synchronous welding compared to asynchronous welding. Optimized process parameters were obtained through orthogonal testing, and subsequent experiments demonstrated that the welding sequence of welding both sides first, followed by the middle, produced lower post-weld equivalent stress and reduced overall joint deformation.

This study systematically investigates the effects of welding current on the macro-morphology, microstructure, mechanical properties, and corrosion resistance of Cu-Mn-Al alloy coatings deposited on 27SiMn steel substrates using Cold Metal Transfer (CMT) technology. The 27SiMn steel is widely applied in coal mining, geology, and engineering equipment due to its high strength and toughness, but its poor corrosion and wear resistance significantly limits service life. To address this issue, a Cu-Mn-Al alloy (high-manganese aluminum bronze) was selected as a cladding material because of its superior combination of mechanical strength, toughness, and excellent corrosion resistance in saline and marine environments. Compared with conventional cladding processes, CMT technology enables low-heat-input deposition, reduces dilution from the substrate, and promotes defect-free coating formation. To the best of our knowledge, this is the first report on the fabrication of Cu-Mn-Al coatings on 27SiMn steel using CMT, aiming to optimize process parameters and establish the relationship between welding current, phase evolution, and coating performance. The experimental results demonstrate that the cladding layer width increases progressively with welding current, whereas the layer height remains relatively stable at approximately 3 mm. At welding currents of 120 A and 150 A, the cladding layer primarily consists of α-Cu, κII, β-Cu₃Al, and α-Cu + κIII phases. At higher welding currents (180 A and 210 A), the α-Cu + κIII phase disappears, accompanied by the formation of petal-shaped κI phase. The peak shear strength (509.49 MPa) is achieved at 120 A, while the maximum average hardness (253 HV) is obtained at 150 A. The 120 A cladding layer demonstrates optimal corrosion resistance. These findings provide new insights into the application of CMT in fabricating Cu-Mn-Al protective coatings on steel and offer theoretical guidance for extending the service life of 27SiMn steel components in aggressive environments.

This study investigates the fabrication of a Cu-Mn-Al alloy coating on 27SiMn steel using Cold Metal Transfer (CMT) technology with an innovative Ar-B(OCH₃)₃ mixed shielding gas, focusing on the effect of the gas flow rate (5–20 L/min). The addition of B(OCH₃)₃ was found to significantly enhance process stability by improving molten pool wettability, resulting in a wider cladding layer (6.565 mm) and smaller wetting angles compared to pure Ar. Macro-morphology analysis identified 10 L/min as the optimal flow rate for achieving a uniform and defect-free coating, while deviations led to oxidation (at low flow) or spatter and turbulence (at high flow). Microstructural characterization revealed that the flow rate critically governs phase evolution, with the primary κI phase transforming from dendritic/granular to petal-like/rod-like morphologies. At higher flow rates (≥15 L/min), increased stirring promoted Fe dilution from the substrate, leading to the formation of Fe-rich intermetallic compounds and distinct spherical Fe phases. Consequently, the cladding layer obtained at 10 L/min exhibited balanced and superior properties, achieving a maximum shear strength of 303.22 MPa and optimal corrosion resistance with a minimum corrosion rate of 0.02935 mm/y. All shear fractures occurred within the cladding layer, demonstrating superior interfacial bonding strength and ductile fracture characteristics. This work provides a systematic guideline for optimizing shielding gas parameters in the CMT cladding of high-performance Cu-Mn-Al alloy coatings.