Effects of relative positioning of energy sources on weld integrity for hybrid laser arc welding

This study is concerned with the effects of laser and arc arrangement on weld integrity for the hybrid laser arc welding processes. Experiments were conducted for a high-strength steel using a 4 kW Nd: YAG laser and a metal active gas (MAG) welding facility under two configurations of arc–laser hybrid welding (ALHW) and laser–arc hybrid welding (LAHW). Metallographic analysis and mechanical testing were performed to evaluate the weld integrity in terms of weld bead geometry, microstructure and mechanical properties. The morphology of the weld bead cross-section was studied and the typical macrostructure of the weld beads appeared to be cone-shaped and cocktail cup-shaped under ALHW and LAHW configurations, respectively. The weld integrity attributes of microstructure, phase constituents and microhardness were analyzed for different weld regions. The tensile and impact tests were performed and fracture surface morphology was analyzed by scanning electron microscope. The study showed that ALHW produced joints with a better weld shape and a more uniform microstructure of lath martensite, while LAHW weld had a heterogeneous structure of lath martensite and austenite.     

Observation of the mechanisms causing two kinds of undercut during laser hybrid arc welding

Two different kinds of undercut were identified when laser hybrid welding hot rolled HSLA-steel in either the as-rolled condition or with the top surface mill scale removed. The presence of mill scale on the steel surface was found to give a sharp angled undercut combined with a sharp oxide inclusion at the edge of the weld which would have the same mechanical effect as a crack in this position. Removal of the surface oxides before welding resulted in the elimination of the oxide inclusions and a more rounded undercut geometry indicative of superior mechanical properties, particularly fatigue life. The mechanisms of the formation of both types of undercut have been analysed by high speed photography and SEM.     

Three—dimensional modelling of the flow and heat transfer in a laminar non—transferred arc plasma torch

By experimental observation we show that the plasma flow and heat transfer within a direct current (DC) nontransferred arc plasma torch always show appreciable three-dimensional (3D) peculiarity even when the geometrical construction of the torch and working gas admission and external electrical collection conditions are completely axisymmetrical.Previous two-dimensional (2D) modelling studies cannot predict the 3D peculiarity of the plasma torch.We have successfully performed 3D modelling,and in this paper we present the modelling results for the plasma flow and heat transfer characteristics in a laminar DC non-transferred are argon plasma torch.The predicted arc-root location on the surface of the torch anode and arc voltage compare favourably with the corresponding experimental results.     

高频调制电弧的声学特性及其细化焊缝组织的应用

以等离子体电弧作为声源,利用高频电流进行调制,激发电弧可以产生超声波。研究了高频调制电弧的激发特性和声场特征,发现调制电弧所发射超声波在激励频段内呈现平坦的幅频特性,激励电流是影响电弧超声强度的主要因素,声压幅值与电弧等离子体流力的变化量成正比,声场呈现轴向强两侧弱的特征。同时介绍了利用电弧激发超声波在改善焊缝组织性能方面的应用。     

Influences of laser in low power YAG laser-MAG hybrid welding process

The influences of laser defocusing amount △z, laser power P, space distance DLA between laser and arc on weld penetration, arc modality and stability are investigated in low power YAG laser and metal active gas （laser-MAG） hybrid welding process. The experimental results indicate that the effects of laser-induced attraction and contraction of MAG arc are emerged in hybrid welding process, which result in the augmentation of hybrid welding energy. When DLA ： -0.5 - 2 mm, △z = -2 - 2 mm and P ≥ 73 W, the synergic efficiency between laser and MAG arc is obvious, the cross section at the root of hybrid arc is contracted and the hybrid weld penetration is increased. The maximal ratio of hybrid/MAG weld penetration is 1.5 and the lowest YAG laser power that augments MAG arc is 73 W. The input of YAG laser makes the stabilities of arc ignition and combustion prominent in hybrid welding process.     

The influence of laser pulse waveform on laser-TIG hybrid welding of AZ31B magnesium alloy

By dividing laser pulse duration into two parts, three kinds of laser waveforms are designed, including a high power density pulse (HPDP) laser in a short duration set at the beginning of the laser waveform. This paper aims to find out the laser pulse waveform and idiographic critical values of HPDP, which can affect the magnesium penetration in laser-tungsten inert gas (TIG) hybrid welding. Results show that when the laser pulse duration of HPDP is not more than 0.4 ms, the welding penetration values of lasers with HPDP are larger than otherwise. Also, the welding penetration values of laser with HPDP have increased by up to 26.1%. It has been found that with HPDP, the laser can form the keyhole more easily because the interaction between laser and the plate is changed, when the TIG arc preheats the plate. Besides, the laser with high power density and short duration strikes on the plates so heavily that the corresponding background power can penetrate into the bottom of the keyhole and maintain the keyhole open, which facilitates the final welding penetration.     

Analysis of plasma characteristics and conductive mechanism of laser assisted pulsed arc welding

This study aims to investigate the arc plasma shape and the spectral characteristics during the laser assisted pulsed arc welding process. The arc plasma shape was synchronously observed using a high speed camera, and the emission spectrum of plasma was obtained by spectrometer. The well-known Boltzmann plot method and Stark broadening were used to calculate the electron temperature and density respectively. The conductive mechanism of arc ignition in laser assisted arc hybrid welding was investigated, and it was found that the plasma current moved to the arc anode under the action of electric field. Thus, a significant parabolic channel was formed between the keyhole and the wire tip. This channel became the main method of energy transformation between the arc and the molten pool. The calculation results of plasma resistivity show that the laser plasma has low resistivity as the starting point of conductive channel formation. When the laser pulse duration increases, the intensity of the plasma radiation spectrum and the plasma electron density will increase, and the electron temperature will decrease.     

Pulsed Nd:YAG laser welding of AISI 304 to AISI 420 stainless steels

The technique to weld AISI 304 stainless steel to AISI 420 stainless steel with a pulsed Nd:YAG laser has been investigated. The main objective of this study was to determine the influence of the laser beam position, with respect to the joint, on weld characteristics. Specimens were welded with the laser beam incident on the joint and moved 0.1 and 0.2 mm on either side of the joint. The joints were examined in an optical microscope for cracks, pores and to determine the weld geometry. The microstructure of the weld and the heat affected zones were observed in a scanning electron microscope. An energy dispersive spectrometer, coupled to the scanning electron microscope, was used to determine variations in (weight %) the main chemical elements across the fillet weld. Vickers microhardness testing and tensile testing were carried out to determine the mechanical properties of the weld. The results of the various tests and examinations enabled definition of the best position for the incident laser beam with respect to the joint, for welding together the two stainless steels.     

双面电弧焊接的传热模型

将等离子焊接(PAW)电弧和钨极氩弧焊(TIG)电弧串接,相对作用于工件的正反面形成双面电弧焊接(DSAW)系统,可以引导焊接电流沿工件厚度方向流过小孔,补偿等离子电弧穿透工件时消耗的能量,以有效地提高等离子弧的穿透能力.综合考虑影响双面电弧焊接正反面熔池几何形状的力学因素,建立了熔池表面变形的控制方程,以此为基础并采用帖体曲线坐标系建立了DSAW焊接传热的数学模型,分析了DSAW,PAW焊接传热的差异,从传热的角度解释了DSAW焊接熔深增加的原因.焊接工艺实验表明,计算结果与实测结果吻合良好. 关键词： 双面电弧焊接(DSAW) 传热模型 熔池表面变形模型     

A study of the radiation of a Nd:YAG laser-MIG hybrid plasma

To study the coupling of a Nd:YAG laser beam and a MIG arc with the spectrum of the plasma, a new hollow probe method is used to collect radiation from specific points within the arc plasma. With the probe, the spatial distributions of the MIG arc radiation with and without the Nd:YAG laser hybrid plasma are collected and analyzed by a fiber spectrometer. Through analysis of the spectrum, radiation in the ultraviolet (Fe II dominated), visible (Fe I dominated) and infra (Ar I dominated) spectral zones are acquired for comparison of the difference between the MIG and Laser-MIG hybrid welding processes. The electronic temperature is calculated using the Boltzmann plot method and the electronic density is calculated using the Stark broadening method. The results show that the Laser-MIG hybrid welding processes cause the plasma energy to focus on the center of the welding arc and approach the welding pool. An ionizing duct abundant with Fe ions will be formed near the position of the impinging laser beam, which makes the welding arc stable. The electronic temperature of the Laser-MIG hybrid welding arc is a little higher than that of the MIG. The electronic density of Laser-MIG hybrid welding is higher than that of the MIG.     

Effect of acoustic field parameters on arc acoustic binding during ultrasonic wave-assisted arc welding

As a newly developed arc welding method, power ultrasound has been successfully introduced into arc and weld pool during ultrasonic wave-assisted arc welding process. The advanced process for molten metals can be realized by utilizing additional ultrasonic field. Under the action of the acoustic wave, the plasma arc as weld heat source is regulated and its characteristics make an obvious change. Compared with the conventional arc, the ultrasonic wave-assisted arc plasma is bound significantly and becomes brighter. To reveal the dependence of the acoustic binding force on acoustic field parameters, a two-dimensional acoustic field model for ultrasonic wave-assisted arc welding device is established. The influences of the radiator height, the central pore radius, the radiator radius, and curvature radius or depth of concave radiator surface are discussed using the boundary element method. Then the authors analyze the resonant mode by this relationship curve between acoustic radiation power and radiator height. Furthermore, the best acoustic binding ability is obtained by optimizing the geometric parameters of acoustic radiator. In addition, three concave radiator surfaces including spherical cap surface, paraboloid of revolution, and rotating single curved surface are investigated systematically. Finally, both the calculation and experiment suggest that, to obtain the best acoustic binding ability, the ultrasonic wave-assisted arc welding setup should be operated under the first resonant mode using a radiator with a spherical cap surface, a small central pore, a large section radius and an appropriate curvature radius.     

Thermal modelling of laser welding and related processes: a literature review

The main emphasis of this review is on thermal modelling and prediction of laser welding in metals. However as similar techniques are employed to model conventional welding processes such as arc, resistance and friction, as well as related processes such as alloying, cladding and surface hardening, part of this review is given over to the modelling of these processes where appropriate. The time frame of the review is up to the year 2002.     

The ultrasonic characteristics of high frequency modulated arc and its application in material processing

To solve the difficulty of introducing traditional ultrasonic transducers to welding molten pool, high frequency current is used to modulate plasma arc and ultrasonic wave is excited successfully. The characteristics of the excited ultrasonic field are studied. The results show that the amplitude-frequency response of the ultrasonic emission is flat. The modulating current is the main factor influencing the ultrasonic power and the sound pressure depends on the variation of arc plasma stream force. Experimental study of the welding structure indicates grain refinement by the ultrasonic emission of the modulated arc and the test results showed there should be an energy region for the arc ultrasonic to get best welding joints.     

微束等离子体弧焊电弧物理特性多场耦合分析

根据磁流体动力学方程组,建立了微束等离子电弧模型,使用有限元分析软件COMSOL进行模拟计算。结果表明,电弧中心温度分布从钨针至焊件整体呈"毛笔"状,其中,喷嘴下方电弧形态呈"钟罩"形,在焊件上温度分布符合高斯分布特征;电弧等离子体在喷嘴内部速度较大,离开喷嘴后,其方向由喷嘴内的竖直向下逐渐变为到达工件时的向四周扩散;电流由焊件表面流出,经过弧柱区域流入钨针下端面,在钨针下端面附近取得最大值;电弧磁通密度分布呈"肺叶"状。最后进行了相应的熔焊试验,试验过程中拍摄的电弧轮廓与仿真电弧形态基本一致。     

双钨极耦合电弧数值模拟

基于流体力学方程组和麦克斯韦方程组, 在合理的边界条件下, 建立了双钨极耦合电弧三维准静态数学模型. 通过对方程组的迭代求解, 获得了不同钨极间距和电弧长度下耦合电弧的温度场、流场、电弧压力和电流密度分布等重要结果, 与已有的实验研究符合良好. 模拟结果表明: 与相同条件下的钨极惰性气体保护焊电弧相比, 双钨极耦合电弧的最高温度和最大等离子流速较低, 阳极表面电弧压力和电流密度峰值明显减小; 钨极间距和弧长对耦合电弧的温度场、流场、电流密度和电弧压力等都具有显著的影响, 且耦合电弧阳极的电弧压力和电流密度分布不能用高斯近似进行描述. 关键词： 耦合电弧 三维模型 数值模拟     

Cr4＋：Nd3＋：YAG自调Q陶瓷激光器输出特性的计算分析

利用Siegman速率方程组，采用自适应变步长龙格一库塔数值方法，对Cr4＋：Nd3＋：YAG自调Q陶瓷激光器的输出特性进行了数值模拟，详细讨论了Nd3＋：YAG陶瓷厚度以及Cr^4＋离子浓度对陶瓷激光器的重复频率、峰值功率、单脉冲能量、脉冲宽度、以及平均输出功率等输出特性的影响。研究结果表明，随着参与作用的Nd^3＋离子数的增加，输出激光脉冲重复频率和平均输出功率均会明显提高；随着Cr^4＋离子浓度的升高，输出激光脉冲重复频率和平均输出功率则会明显下降。     

Improvement of laser keyhole formation with the assistance of arc plasma in the hybrid welding process of magnesium alloy

In the previous work, low-power laser/arc hybrid welding technique is used to weld magnesium alloy and high-quality weld joints are obtained. In order to make clear the interactions between low-power laser pulse and arc plasma, the effect of arc plasma on laser pulse is studied in this article. The result shows that the penetration of low-power laser welding with the assistance of TIG arc is more than two times deeper than that of laser welding alone and laser welding transforms from thermal-conduction mode to keyhole mode. The plasma behaviors and spectra during the welding process are studied, and the transition mechanism of laser-welding mode is analyzed in detail. It is also found that with the assistance of arc plasma, the threshold value of average power density to form keyhole welding for YAG laser is only 3.3×10⁴ W/cm², and the average peak power density is 2.6×10⁵ W/cm² in the present experiment. Moreover, the distribution of energy density during laser pulse is modulated to improve the formation and stability of laser keyholes.     

G-M制冷机气缸组件焊接工艺初探

气缸组件由整体式改为分体式,就面临一个焊接问题。二级气缸级间法兰与一级气缸缸体相连,采用微热氩弧焊焊接;用焊接芯棒保证一、二级气缸的同轴度及气缸组件的长度尺寸;焊接时使用螺孔定位工装保证一、二级冷头上各螺孔在图示位置,不得错位。对气缸组件的焊接工艺作了初步的分析与探索。     

Three-dimensional hybrid model for predicting air-coupled generation of guided waves in composite material plates

For contact-less, non-destructive testing (NDT) purposes using air-coupled ultrasonic transducers, it is often required to numerically simulate the propagation of ultrasonic waves in solid media, and their coupling through air with specific transducers. At that point, one could simulate the propagation in the air and then in the solid component, using a Finite Element (FE) model. However, when three-dimensional (3D) modeling becomes necessary, such a solution reveals to be extremely demanding in terms of number of degrees of freedom and computational time. In this paper, to avoid such difficulties, the propagation in air from an ultrasonic transmitter to a tested solid plate is modeled in 3D using a closed-form solution. The knowledge of the transducer characteristics (diameter, frequency bandwidth, efficiency in Pa/V) allows the spatial distribution and actual pressure (in Pa) of the acoustic field produced in the air to be predicted, for a given input voltage. This pressure field is applied in turn as a boundary condition in a 3D FE model, to predict the plate response (displacement and stress guided beams) for a given distance between the transmitter and the plate, and for a given angle of orientation of the transmitter with respect to the plate. The FE model is so restricted to modeling of the solid structure only, thus reducing very significantly the number of degrees of freedom and computational time. The material constituting the plate is considered to be an anisotropic and viscoelastic medium. To validate the whole modeling process, an air-coupled ultrasonic transducer is used and oriented at a specific angle chosen for generating one specific Lamb mode guided along a composite plate sample, and a laser probe measures the normal velocity at different locations on the surface of the plate. In the field of NDT, it is generally suitable to excite a pure Lamb mode in order to ease the interpretation of received signals that would represent waves scattered by defects. After a validation step, the numerical model is then used to investigate the effect of the material anisotropy on the purity of the incident guided mode.     

Laser welding of glasses using a nanosecond pulsed Nd:YAG laser

This work reports on laser welding of two 1 mm thickness borosilicate glasses through the irradiation with a nanosecond pulsed laser, as a novel alternative to the use of ultrashort pulsed lasers for welding of transparent materials. Two different methodologies were investigated and compared in terms of interface quality. In a first approach, the glasses were joined without any absorbing intermediate layer. However, the bond interface possesses defects. To improve the resulting bond interface, the use of a titanium ultrathin intermediate layer was proposed to weld the glasses substrates, acting as a sealant between them. The laser parameters were optimized to achieve the best joining conditions of the Ti film. The use of the Ti layer gives rise to a bond interface more homogeneous and free of damages. As a further step, thin glasses of 86 µm thickness, of great technological value, were joined through the Ti film as well. The joined interfaces were inspected through optical microscopy and scanning electron microscopy (SEM) while the bond quality was evaluated by Scanning Acoustic Microscopy (SAM).