大功率盘形激光焊飞溅特征分析

焊接过程的在线监控是保证激光焊接质量的关键, 为此, 首先要找到焊接过程传感特征量变化规律以及与焊缝质量间的关系. 飞溅是大功率盘型激光焊接过程中的一个重要现象, 其特征与焊接质量、焊接过程稳定性以及能量利用率等有着密切的联系. 以大功率盘形激光焊接304不锈钢为试验对象, 研究焊接过程中的飞溅特征. 在紫外波段和可见光波段应用高速摄像机摄取焊接过程中产生飞溅的瞬态特征, 通过计算机图像处理技术分析飞溅的数量、面积、行程和质心高度特征参量. 以焊件熔宽作为衡量焊接质量与焊接过程稳定性的因素, 对飞溅特征量进行线性和高次拟合, 研究飞溅特征参量的波动规律, 并与焊件熔宽的变化对比, 探索焊接过程的飞溅特征参量变化规律. 试验结果表明, 根据飞溅特征量变化规律能够对大功率盘形激光焊接304不锈钢板焊接质量做出动态评估, 为实现焊接质量的在线监控提供了试验依据.     

大功率光纤激光焊焊缝跟踪偏差红外检测方法

精确控制激光束使其始终对准并跟踪焊缝是保证激光焊接质量的前提.针对大功率(激光功率10 kW)光纤激光焊接304型不锈钢紧密对接焊缝(间隙为0-0.1 mm),研究一种基于红外热像的焊缝跟踪偏差检测新方法. 采用红外传感高速摄像机摄取焊接区域熔池红外动态热像,分析激光束对准和偏离焊缝中心时的熔池温度分布和红外辐射特性,以熔池匙孔形变参数和热堆积效应参数作为激光束与焊缝中心偏差检测特征值,通过图像识别技术研究和分析特征值与焊缝偏差之间的关系. 激光焊接试验结果表明,熔池匙孔形变参数和热堆积效应参数与焊缝偏差 关键词： 大功率光纤激光焊 焊缝跟踪偏差 红外热像 检测     

大功率盘形激光焊接飞溅动态识别和特征分析

提出了一种识别飞溅动态并基于飞溅特征分析焊接状态的方法。以304不锈钢板为试验对象,进行大功率盘形激光平板堆焊试验。利用高速相机捕捉紫外波段和可见光波段的飞溅图像,通过图像处理提取飞溅特征参数,包括质心位置、面积、灰度、平均灰度和半径。基于飞溅特征参数建立飞溅搜索信息库和相似度函数,用于识别飞溅、计算飞溅体积和灰度以及评估焊接状态。通过焊缝宽度与飞溅特征信息的比较,研究焊接状态与飞溅特征参数之间的内在关系。对飞溅特征与焊接状态之间关系进行了试验分析,结果表明,激光焊接过程中飞溅的体积和灰度值增大,焊缝宽度会相应减小,通过飞溅特征参数可有效监测和评估大功率盘形激光焊接过程的状态。     

大功率盘形激光焊接飞溅动态识别和特征分析（英文）

提出了一种识别飞溅动态并基于飞溅特征分析焊接状态的方法。以304不锈钢板为试验对象,进行大功率盘形激光平板堆焊试验。利用高速相机捕捉紫外波段和可见光波段的飞溅图像,通过图像处理提取飞溅特征参数,包括质心位置、面积、灰度、平均灰度和半径。基于飞溅特征参数建立飞溅搜索信息库和相似度函数,用于识别飞溅、计算飞溅体积和灰度以及评估焊接状态。通过焊缝宽度与飞溅特征信息的比较,研究焊接状态与飞溅特征参数之间的内在关系。对飞溅特征与焊接状态之间关系进行了试验分析,结果表明,激光焊接过程中飞溅的体积和灰度值增大,焊缝宽度会相应减小,通过飞溅特征参数可有效监测和评估大功率盘形激光焊接过程的状态。     

基于光谱分析的CO_2激光+脉冲GMAW复合焊峰值状态激光能量传输研究

在激光+脉冲GMAW复合焊接过程中,焊丝端部金属熔化产生大量的金属蒸汽,导致等离子体中电子、粒子的扩散现象加剧,使得激光的传输模式和工件对激光能量的吸收率和吸收模式发生变化。基于光谱分析的方法得到了复合焊接峰值状态的电子密度和温度分布,通过高速摄影分析了不同焊接模式下等离子体形态的变化,结合Beer-Lambert吸收定律计算了不同焊接模式下激光的吸收率。结果表明,在复合焊过程中,由于焊丝端部金属被熔化,焊丝的金属蒸汽进入激光等离子体内部,导致激光匙孔上方电子密度进一步提高,等离子体吸收激光能量能力增强,使得激光的传输效率从纯激光焊的94.16%降低到了CO_2激光+脉冲GMAW复合焊的85.84%。     

激光焊接熔透特征信号同轴增效提取方法研究

熔透检测是实现高功率激光焊接质量在线控制的重要环节,但由于介观尺度下的低辐值熔透特征信号产生于激光匙孔底部被匙孔喷射物质和周围干扰信号完全掩盖,熔透状态难以被直接获取,常规检测多以间接测量为主。将光谱透视技术、红外显微成像技术、光电传感技术及空间定位提取技术相结合,提出一种激光焊接熔透特征信号同轴增效提取方法。以高功率激光在匙孔内壁激发的荧光辐射源作为直接检测信号,利用不同发光体的谱段特性在红外谱段有效分离并抑制激光焊接匙孔上方的等离子体、金属蒸汽焰、粒子团簇等强干扰信号,使红外荧光信号得到有效增强,实现光谱透视显像效果。同时采用自行研制的激光焊接同轴显微光路系统,利用红外显微成像原理提取到匙孔内壁受激辐射荧光的红外显微实像。并以此为基础对高功率激光焊接熔透状态与匙孔内部影像特征进行关联研究,发现与熔透状态直接相关的低辐射值特征现象及特征区域的存在。通过视觉辅助定位调节和熔透特征位置试验矫正等寻位方式,依次提高定位精度,直至将传感器光电感应芯片高精度定位至荧光辐射实像中的熔透特征区域。由此通过光谱透视-显微成像-介观寻位萃取的逐层光学分离方式,实现了对匙孔熔透特征数据的精准提取和最大化增强。试验结果表明,基于多种光谱及光学处理技术复合应用的大功率固体激光焊熔透特征同轴增效提取方法对激光熔透特征信号增强效果显著,可作为一种新型的高功率激光焊接熔透在线检测手段。     

不同焊接位置对5A90铝锂合金激光焊接质量的影响(英)

针对铝锂合金激光焊接产生的成形不良和气孔缺陷,探究不同焊接位置对焊缝成形及气孔的影响,并对比分析不同焊接位置熔池受力状态、熔融金属流动和小孔动态行为,解释缺陷形成及其抑制机理。研究发现:不同焊接位置熔池受力状态和熔融金属流动决定焊缝成形。平焊时焊缝成形差、下榻严重;横焊时背面焊缝不连续,有飞溅;立向上焊时背面焊缝内凹严重;立向下焊可得到最优焊缝成形和最优的气孔缺陷。焊缝气孔受小孔动态行为影响,不同焊接位置气孔随热输入的变化规律一致,气孔先增后减,在仅熔池透状态下有气孔最大值。立上焊时小孔不稳定,焊缝气孔多且分布杂乱;立向下焊时小孔稳定性高,气孔最少,主要分布在焊缝中心线上。     

基于4 kW YAG激光器的激光拼焊焊接工艺

分析了激光拼焊工艺特征,重点研究了在大功率固体激光器条件下,激光拼焊焊接工艺中激光功率、焊接速度和离焦量等因素变化对焊接质量的影响,得出了变化规律曲线。并系统全面地研究了目前汽车常用板材全厚度系列激光拼焊工艺,采用叠代寻优的方法获得到了适用于全自动激光拼焊生产线的优化工艺规范。     

不同焊接位置对5A90铝锂合金激光焊接质量的影响（英文）

针对铝锂合金激光焊接产生的成形不良和气孔缺陷,探究不同焊接位置对焊缝成形及气孔的影响,并对比分析不同焊接位置熔池受力状态、熔融金属流动和小孔动态行为,解释缺陷形成及其抑制机理。研究发现:不同焊接位置熔池受力状态和熔融金属流动决定焊缝成形。平焊时焊缝成形差、下榻严重;横焊时背面焊缝不连续,有飞溅;立向上焊时背面焊缝内凹严重;立向下焊可得到最优焊缝成形和最优的气孔缺陷。焊缝气孔受小孔动态行为影响,不同焊接位置气孔随热输入的变化规律一致,气孔先增后减,在仅熔池透状态下有气孔最大值。立上焊时小孔不稳定,焊缝气孔多且分布杂乱;立向下焊时小孔稳定性高,气孔最少,主要分布在焊缝中心线上。     

基于光谱诊断的脉冲GMAW焊金属蒸汽动态扩散行为研究

理解脉冲GMAW焊电弧物理的动态特性对解释这一焊接方法的内在机理及获取优化控制策略有重要意义,通过在高速摄影前加窄带滤波片的方法研究了脉冲GMAW焊接过程中不同粒子的扩散行为,同时采用光谱仪研究了不同状态下金属与蒸汽保护气氛谱线的强度分布信息,采用气体状态方程、等离子体准中性方程、和Saha方程计算了脉冲GMAW焊接峰值和基值两种不同状态下的金属蒸汽浓度分布。研究结果显示,在峰值时刻,金属蒸汽被约束在电弧中心1 mm左右的范围内,当电流从峰值跳转到基值时刻,金属蒸汽从中心扩散到电弧外围区域,峰值时刻中心金属浓度约为75%,而基值仅为35%左右。     

Spectral diagnostics of a vapor-plasma plume produced during welding with a high-power ytterbium fiber laser

We have conducted spectroscopic studies of the welding plasma formed in the process of welding with an ytterbium fiber laser delivering output power of up to 20 kW. The influence of shielding gases (Ar, He) on different parts of the welding plume is investigated. The absorption coefficient of the laser radiation by the welding-plume plasma is estimated. Scattering of 532-nm probe radiation from particles of the condensed metal vapor within the caustic of a high-power fiber laser beam is measured. Based on the obtained results, conclusions are made on the influence of the plasma formation and metal vapor condensation on the radiation of the high-power fiber laser and the stability of the welding process.     

激光感生等离子体特性的三维数值模拟

在激光焊接过程中,作用于金属工件表面的高强度激光会引起材料的强烈蒸发,金属蒸汽与入射激光相互怍用,又会引起金属蒸汽部分电离,形成激光感生等离子体。本文采用三维模拟方法,考虑保护气和侧吹气的影响,对激光感生等离子体中的温度与速度分布进行了研究。     

Parametric optimisation and microstructural analysis on high power Yb-fibre laser welding of Ti–6Al–4V

In this work thin sheets of Ti–6Al–4V were full penetration welded using a 5 kW fibre laser in order to evaluate the effectiveness of high power fibre laser as a welding processing tool for welding Ti–6Al–4V with the requirements of the aircraft industry and to determine the effect of welding parameters including laser power, welding speed and beam focal position on the weld microstructure, bead profile and weld quality. It involved establishing an understanding of the influence of welding parameters on microstructural change, welding defects, and the characteristics of heat affected zone (HAZ) and weld metal (WM) of fibre laser welded joints. The optimum range of welding parameters which produced welds without cracking and porosity were identified. The influence of the welding parameters on the weld joint heterogeneity was characterised by conducting detailed microstructural analysis.     

Analysis of the correlation between plasma plume and keyhole behavior in laser metal welding for the modeling of the keyhole geometry

The process of laser metal welding is widely used in industry. Nevertheless, there is still a lack of complete process understanding and control. For analyzing the process we used two high-speed cameras. Therefore, we could image the plasma plume (which is directly accessible by a camera) and the keyhole (where most of the process instabilities occur) during laser welding isochronously. Applying different image processing steps we were able to find a correlation between those two process characteristics. Additionally we imaged the plasma plume from two directions and were able to calculate a volume with respect to the vaporized material the plasma plume carries. Due to these correlations we are able to conclude the keyhole stability from imaging the plasma plume and vice versa. We used the found correlation between the keyhole behavior and the plasma plume to explain the effect of changing laser power and feed rate on the keyhole geometry. Furthermore, we tried to outline the phenomena which have the biggest effect on the keyhole geometry during changes of feed rate and laser power.     

3D transient multiphase model for keyhole,vapor plume,and weld pool dynamics in laser welding including the ambient pressure effect

The physical process of deep penetration laser welding involves complex, self-consistent multiphase keyhole, metallic vapor plume, and weld pool dynamics. Currently, efforts are still needed to understand these multiphase dynamics. In this paper, a novel 3D transient multiphase model capable of describing a self-consistent keyhole, metallic vapor plume in the keyhole, and weld pool dynamics in deep penetration fiber laser welding is proposed. Major physical factors of the welding process, such as recoil pressure, surface tension, Marangoni shear stress, Fresnel absorptions mechanisms, heat transfer, and fluid flow in weld pool, keyhole free surface evolutions and solid–liquid–vapor three phase transformations are coupling considered. The effect of ambient pressure in laser welding is rigorously treated using an improved recoil pressure model. The predicated weld bead dimensions, transient keyhole instability, weld pool dynamics, and vapor plume dynamics are compared with experimental and literature results, and good agreements are obtained. The predicted results are investigated by not considering the effects of the ambient pressure. It is found that by not considering the effects of ambient pressure, the average keyhole wall temperature is underestimated about 500 K; besides, the average speed of metallic vapor will be significantly overestimated. The ambient pressure is an essential physical factor for a comprehensive understanding the dynamics of deep penetration laser welding.     

Real-time monitoring of laser welding of galvanized high strength steel in lap joint configuration

Two different cases regarding the zinc coating at the lap joint faying surface are selected for studying the influence of zinc vapor on the keyhole dynamics of the weld pool and the final welding quality. One case has the zinc coating fully removed at the faying surface; while the other case retains the zinc coating on the faying surface. It is found that removal of the zinc coating at the faying surface produces a significantly better weld quality as exemplified by a lack of spatters whereas intense spatters are present when the zinc coating is present at the faying surface. Spectroscopy is used to detect the optical spectra emitted from a laser generated plasma plume during the laser welding of galvanized high strength DP980 steel in a lap-joint configuration. A correlation between the electron temperature and defects within the weld bead is identified by using the Boltzmann plot method. The laser weld pool keyhole dynamic behavior affected by a high-pressure zinc vapor generated at the faying surface of galvanized steel lap-joint is monitored in real-time by a high speed charge-coupled device (CCD) camera assisted with a green laser as an illumination source.     

大口径薄片激光器中的谐振模式及光束质量诊断

基于自再现原理,利用菲涅耳-基尔霍夫衍射积分方程,引入腔镜失调、激光介质上的增益分布以及光阑口径,采用本征矢量法分析了大口径平凹腔薄片激光器的本征模式,并计算了相应的光束质量因子M2.建立了千瓦级薄片激光系统和光纤扫描光斑诊断装置,开展了高功率激光输出特性研究.结果表明,在大口径高功率平凹腔中多个本征模式可同时起振,获...