Porosity distribution and mechanical response of laser-MIG hybrid butt welded 6082-T6 aluminum alloy joint

6082-T6 aluminum alloy with thickness of 6 mm were welded by laser-MIG hybrid welding. The effects of welding parameters on the porosity distribution, the correlations between the porosity distribution and me-chanical properties were comprehensively investigated. The porosities mainly appeared near the fusion line of the arc zone when the arc current larger than 140 A, and which mainly existed in the center of the laser zone with other unsuitable parameters. Adopting low welding speed and setting heat source distance as around 3 mm were beneficial for the reduction of the porosity rate. The laser power, defocus distance, fit-up gap and gas flow rate had less effects on the porosity distribution. The average tensile strength of the joints without porosities was 260 MPa, which decreased to 224 MPa and 202 MPa as the porosity rate increased to 5.1% and 8.9%. The tensile specimens fractured at the heat affected zone or in the weld center when the porosity rates less or greater than 3%, and the fracture feature was diverted from ductile fracture to ductile and brittle mixed mode as the porosity rate increasing. The fatigue strength reduced from 113 MPa to 56 MPa when the porosity rate increased from 0% to 8.9%, while the porosity position had little effect on it. The fracture initiated in the weld surface when the joints without porosity, and which initiated near the porosity when the porosities existed in the joint.