The effects of magnesium content in dual-beam Nd:YAG laser welding of aluminum alloys have been examined. Although weld dimensions decreased with increasing magnesium content at speeds of less than 6 m/min, at higher speeds, weld dimensions increased with increasing magnesium content. For a given power and speed, penetration increased as magnesium content increased. In all cases, weld dimensions decreased as welding speed increased. However, the effect of increased speed was less with increased magnesium content. At equal speeds and powers with full penetration, increasing magnesium content decreased the melting ratio. The different effects of magnesium led to a peak in melting ratio versus travel speed, which occurred at higher speeds with higher magnesium content.
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