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%。     

金属杂质粒子诱导薄膜的损伤机理研究

薄膜内的杂质粒子极易诱导薄膜损伤,研究了金属粒子诱导HfO₂薄膜损伤的特征,并基于金属粒子的热力学过程进行了分析。金属粒子对激光的强烈吸收将引起薄膜的熔化、气化以及电离,从而引起薄膜的剥离和脱落,形成圆状坑点;金属粒子对激光的吸收、热扩散以及热膨胀效应与其尺寸等密切相关;从温升规律分析,在相同激光能量辐照下,粒子大小引起的温升不同,从而形成大小不一的点坑状破坏点,且存在一个温升效应最强的粒径,最易引起薄膜的损伤;从金属粒子激光等离子体的辐射效应分析,金属粒子的辐射谱主要集中在紫外部分,辐射光子能量比入射激光光子能量强,具有更强的电离能力,从而加剧了薄膜的去除。     

激光对金属铜微孔加工的热力学过程研究

采用纳秒激光脉冲对铜金属进行了打孔实验,对微孔形貌进行了观察并对其热力学过程进行了相应的分析。研究表明,微孔的形貌是由凹坑和周围隆起组成,坑深随着脉冲能量的增加而增加。热力学分析表明,激光辐照金属打孔需要两个基本条件：一是激光脉冲能量的沉积,使金属材料发生熔化、汽化以及电离等相变,使得材料更容易去除;激光等离子体作为二次热源会更有效把激光脉冲能量耦合到金属表面;二是激光等离子体的冲击波效应,这种效应会把发生相变的材料有效及时排出,从而有效形成微孔。     

纳秒紫外重复脉冲激光烧蚀单晶硅的热力学过程研究

采用波长为355 nm的纳秒紫外重复脉冲激光对单晶硅片进行了盲孔加工实验, 观测了随脉冲增加激光烧蚀硅片的外观形貌和盲孔孔深、孔径的变化规律, 并对紫外激光辐照硅片的热力学过程进行了分析. 研究结果表明:紫外激光加工硅盲孔是基于热、力效应共同作用的结果, 热效应会使得硅材料熔化、气化甚至发生电离产生激光等离子体,为材料的去除提供条件;激光等离子体冲击波以及高温气态物向外膨胀会对熔化材料产生压力致使其向外喷射,为重复脉冲的进一步烧蚀提供了条件;力效应主要沿着激光传输的方向,垂直于硅表面,使得去除部位主要集中在孔的深度方向,达到较高的孔径比,实验观察孔径比可达8:1;此外,激光等离子体的产生也阻止了激光对靶面的作用,加之随孔深的增加激光发生散焦,使得烧蚀深度有一定的限制,实验观察烧蚀脉冲个数在前100个时加工效率较高.     

激光诱导铝基碳纳米管薄膜及场发射性能

结合电泳沉积和激光纳米焊接技术在常温下成功制备了铝基单壁碳纳米管(SWCNTs-Al)薄膜。首先,将单壁碳纳米管电泳沉积到铝片基底上,再使用皮秒脉冲激光构建二者的可靠连接。对SWCNTsAl薄膜进行场发射性能测试,开启电压从焊接前的5.1V/μm降低到2.1V/μm,发射电流密度显著提高且更加稳定。这主要是激光纳米焊接后界面接触阻抗减小,场致电子发射更容易实现的结果。基于SWCNTs-Al薄膜的表面形貌图和场发射性能测试结果,确定了最优的激光纳米焊接参数。     

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。     

激光烧蚀硅表面的发射光谱分析

研究了不同能量的纳秒激光脉冲聚焦到单晶硅片上时,激光等离子体的自由电子密度和温度以及损伤形貌随激光脉冲能量增加的变化规律。研究结果表明：激光脉冲击穿硅介质产生的激光等离子体的体积以及自由电子密度和温度大小,决定了硅表面损伤的形貌特点和大小。自由电子密度和温度的变化特点是：随着激光脉冲能量的增加,激光等离子体的体积不断增大,自由电子温度缓慢增加而密度基本不变。又由于激光等离子体的自由电子密度和温度呈现从中心到边缘由大到小的变化趋势,所以损伤形貌总的特点是内部区域的熔化非常充分,形成明显的周期性排列的规则条纹,且条纹的排列趋势呈现环状;中部区域熔化不充分,形成条纹不很规则;边缘区域处分界明显,有时出现等离子体产生喷溅变色痕迹。     

特殊构件环焊缝射线检测工艺

激光焊接是利用激光熔化母材本身金属来填充焊缝，因此激光焊缝表面没有余高，并有少许凹陷，由于构件结构的特殊性，有关技术要求焊缝的焊接深度仅为16mm，焊缝宽度不得大于6mm，而实际上焊缝区域的母材厚度约为6-12．5mm变化，焊缝尺寸相对于母材厚度很小，造成焊缝在底片上形成的影像不明显。简体内部密封并以其他材料填充，在进行射线检测时射线不可能采取双壁单影法透照对焊缝实施检测，只能采用单壁单影的透照方法。另外，靠近简体内侧加工有工艺弧度，在射线透射方向上母材厚度有很大变化，     

激光照射金颗粒在散射效应下的相变传热

采用二维双温度模型结合散射作用所引起颗粒表面光强不均匀分布的结果,对单脉冲激光垂直照射金颗粒的相变传热进行研究,通过将界面能量平衡方程,成核动力学的界面追踪法相耦合来确定固液界面的位置并研究激光参数对烧结过程的影响.结果表明：当激光垂直照射金颗粒时,熔化现象主要发生在颗粒的两极且底部熔化开始时间早,熔化体积也比较小.激光的脉宽越短熔化开始时间越早,熔化体积越大.提高激光的能量密度,颗粒的熔化体积也随之增加.     

激光刻蚀银纳米粒子岛膜的SERS特性

利用激光刻蚀的方法,通过改变激光脉冲的能量,制备出一系列的纳米金属银胶体。将银胶体沉积在铝基底上形成一层银岛膜。用紫外—可见吸收光谱、SEM及拉曼光谱对银胶体和银岛膜进行了表征。研究结果表明,刻蚀所用激光脉冲的能量影响胶体中银颗粒的分布;不同能量下制备的胶体所形成的银岛膜具有不同的表面增强效果;该岛膜具有增强效果优异、制备简便等特点。     

约束靶面黑漆涂层对激光冲击波的影响

 介绍了约束靶表面的黑漆涂层对激光冲击波的影响。激光功率密度 10⁹W/cm²量级，脉宽33ns，波长1.06μm。靶材选用两种不同厚度的铜和铝，靶表面用有机玻璃约束。通过对冲击波压力的直接测量发现，涂层不仅可以增加激光冲击波压力，而且还影响冲击波的演化过程。比较有无涂层的靶面SEM照片发现，黑漆涂层能有效地保护激光辐照表面，使之不受激光烧蚀。     

Optimization of weld bead geometry in laser welding with filler wire process using Taguchi’s approach

In the present work, laser welding with filler wire was successfully applied to joining a new-type Al–Mg alloy. Welding parameters of laser power, welding speed and wire feed rate were carefully selected with the objective of producing a weld joint with the minimum weld bead width and the fusion zone area. Taguchi approach was used as a statistical design of experimental technique for optimizing the selected welding parameters. From the experimental results, it is found that the effect of welding parameters on the welding quality decreased in the order of welding speed, wire feed rate, and laser power. The optimal combination of welding parameters is the laser power of 2.4 kW, welding speed of 3 m/min and the wire feed rate of 2 m/min. Verification experiments have also been conducted to validate the optimized parameters.     

Characteristics of coated copper wire specimens using high frequency ultrasonic complex vibration welding equipments

Welding characteristic of thin coated copper wires were studied using 40, 60, 100 kHz ultrasonic complex vibration welding equipments with elliptical to circular vibration locus. The complex vibration systems consisted of a longitudinal-torsional vibration converter and a driving longitudinal vibration system. Polyurethane coated copper wires of 0.036 mm outer diameter and copper plates of 0.3 mm thickness and the other dimension wires were used as welding specimens. The copper wire part is completely welded on the copper substrate and the insulated coating material is driven from welded area to outsides of the wire specimens by high frequency complex vibration.     

Interface microstructure and mechanical properties of laser welding copper–steel dissimilar joint

Relatively the high reflectivity of copper to CO₂ laser led to the difficulty in joining copper to steel using laser welding. In this paper, a new method was proposed to complete the copper–steel laser butt welding. The scarf joint geometry was used, i.e., the sides of the copper and steel were in obtuse and acute angles, respectively. During the welding process, the laser beam was fixed on the steel side and the dilution ratio of copper to steel was controlled by properly selecting the deviation of the laser beam. The offset of laser beam depended on the scarf angle between the copper and steel, the thickness of plate and the processing parameters used in the laser welding. The microstructure near the interface between Cu plate and the intermixing zone was investigated. Experimental results showed that for the welded joint with high dilution ratio of copper, there was a transition zone with numerous filler particles near the interface. However, if the dilution ratio of copper is low, the transition zone is only generated near the upper side of the interface. At the lower side of the interface, the turbulent bursting behavior in the welding pool led to the penetration of liquid metal into Cu. The welded joint with lower dilution ratio of copper in the fusion zone exhibited higher tensile strength. On the bases of the microstructural evaluation at the interface of the welded joint, a physical model was proposed to describe the formation mechanism of the dissimilar joint with low dilution ratio of copper.     

表面绝缘混合平面丝阵Z箍缩激光阴影图像诊断

基于脉冲半高全宽约为9 ns、波长为532 nm的Nd:YAG激光器,采用条纹相机和商用数码相机两种记录设备,建立了时间分辨和时间积分两种模式的激光阴影图像诊断系统,在"强光一号"装置上对表面绝缘混合平面丝阵Z箍缩等离子体开展了实验研究.实验结果表明:在融蚀过程中表面绝缘金属丝冕等离子体发展较普通金属丝慢,在t=44ns到t=56ns之间,其平均膨胀速度分别为1.1×104m·s-1和1.7×104m·s-1;在等离子体滞止前10 ns的快速聚爆过程中,表面绝缘金属丝和普通金属丝两侧的平均聚爆速度分别为5.5×105m·s-1和9.3×105m·s-1,表面绝缘一侧等离子体滞止时间小于普通金属丝一侧,分别为5.9 ns和9.5 ns;等离子体碰撞分界线偏向于表面绝缘一侧,滞止时形成的磁流体不稳定性结构类似.     

基于微蒸发腔制冷的大功率激光二极管制冷组件

利用节流的高压冷却介质在微蒸发腔内相变吸热,设计了一种用于大功率激光二极管制冷的封装组件。该组件采用高热导的无氧铜,用精密线切割、化学腐蚀等技术制作微蒸发腔,再通过自制的焊接设备完成制冷组件的封装。按照大功率激光二极管条的发热模型,理论上对微蒸发腔制冷组件的温度分布进行了数值模拟,结果与60 W激光二极管条的散热实验符合较好,得到制冷剂流量为23 m L/min时的热阻为0.289℃/W。     

Fiber laser welding of austenitic steel and commercially pure copper butt joint

The fiber laser welding of austenitic stainless steel and commercially pure copper in butt joint configuration without filler or intermediate material is presented. In order to melt stainless steel directly and melt copper via heat conduction a defocused laser beam was used with an offset to stainless steel. During mechanical tests the weld seam was more durable than heat affected zone of copper so samples without defects could be obtained. Three process variants of offset of the laser beam were applied. The following tests were conducted: tensile test of weldment, intermediate layer microhardness, optical metallography, study of the chemical composition of the intermediate layer, fractography. Measurements of electrical resistivity coefficients of stainless steel, copper and copper–stainless steel weldment were made, which can be interpreted or recalculated as the thermal conductivity coefficient. It shows that electrical resistivity coefficient of cooper–stainless steel weldment higher than that of stainless steel. The width of intermediate layer between stainless steel and commercially pure copper was 41–53 µm, microhardness was 128–170 HV_0.01.     

Influence of water environment on paint removal and the selection criteria of laser parameters

Laser paint removal in a water environment does not diffuse ablation pollution products into air. Characteristics of water, such as high specific heat and heat flux, generate different effects of the laser paint removal than in an air environment. In this study, the effects of air and water environments on the mechanism and effect of laser paint removal are analyzed and compared experimentally and theoretically. In air, thermodynamic ablation causes removal of paint, whereas in water, stress coupled with plasma shock waves cause tear and splash removal of paint layers after fracture and damage. Fracture and pressure thresholds of the paint and substrate, respectively, indicate the optimum energy density range for laser paint removal in water, providing a reference for engineering applications.     

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。     

Removing paint from a metal substrate using a flattened top laser

In this paper,we investigate laser cleaning using a flattened top laser to remove paint coating from a metal substrate.Under the irradiation of a flattened top laser,the coating paint of the metal substrate can be removed efficiently by laser induced ablation,stress,and displacement force.The temperature distribution,stress,and displacement are calculated in the coating layer and substrate using finite element analysis.The effects of a Gaussian laser and a flattened top laser and the results of different diameters of laser spot are compared.The investigation shows that the flattened top laser can reduce the substrate damage and enhance the cleaning efficiency.This method meets the need of large area industrial cleaning applications by optimizing the flattened top laser parameters.