The influence of shielding gas in hybrid LASER-MIG welding

Hybrid LASER-GMAW welding technique has been recently studied and developed in order to meet the needs of modern welding industries. The two sources involved in this process play, in fact, a complementary role: fast welding speed, deep bead penetration and high energy concentration can be achieved through the LASER beam, while gap bridgeability and cost-effectiveness are typical of the GMAW process.Particularly interesting, in this context, is the CO₂ LASER-MIG welding which differs from the Nd:YAG LASER-MIG technique for the high powers that can be exploited and for the good power/cost ratio of the process.This paper is a part of a wide study on the hybrid CO₂ LASER-MIG welding and investigates the influence of the shielding gas both on the stability of the process and on the dimensional characteristics of the weld bead. Two different parameters have been taken into consideration in order to develop this analysis: the shielding gas composition and the shielding gas flow.The experiment, performed on AISI 304 stainless steel plates, has been planned exploiting design of experiment techniques. The results have been analyzed through a statistical approach in order to determine the real influence of each parameter on the overall process.     

Microstructure characteristics of laser-MIG hybrid welded mild steel

To deepen the understanding of laser-arc hybrid welding, the weld shape and microstructure characteristics of laser-metal inert gas hybrid welded mild steel were analyzed. The results showed typical hybrid weld could be classified as two parts: the wide upper zone and the narrow nether zone, which were defined as arc zone and laser zone, respectively. In the hybrid weld, the microstructure, alloy element distribution and microhardness all have evident difference between laser zone and arc zone. The microstructure of arc zone consists of coarse columnar dendrite and fine acicular dendrite between the columnar dendrites, but that of laser zone is composed of fine equiaxed dendrite in weld center and columnar dendrite around the equiaxed dendrite. Compared to arc zone, laser zone has finer grain size, higher microhardness, smaller alloy element content in the fusion zone and narrower heat affected zone. The discussions demonstrated that the observed difference was caused by the difference of temperature gradient, crystallizing and the effects of arc pressure on the molten pool between laser zone and arc zone.     

Effect of welding wires on microstructure and mechanical properties of 2A12 aluminum alloy in CO2 laser-MIG hybrid welding

This paper represented the effect of welding wires on microstructure and mechanical properties of 2A12 aluminum alloy in CO₂ laser-metal inter gas (MIG) hybrid welding. Plates of 2A12 aluminum alloy were welded by ER4043 and ER2319 welding wires, respectively. Full penetration joints without any defects were produced. The X-ray diffraction was used to analyze the phase composition, while the scanning electron microscopy (SEM) was conducted to study the microstructure, segregation behaviors of major alloying elements and the eutectics formed at dendrite boundaries in the joints. The results showed that silicon and copper were concentrated at the dendrite boundaries and α-Al + Si + Al₂Cu + Mg₂Si eutectic was formed if the ER4043 welding wire was used. However, only copper was concentrated at the dendrite boundaries and α-Al + θ eutectic was formed by ER2319 welding wire. Finally, the tensile tests were performed and the fracture surfaces were analyzed. The results showed that the joint efficiency by ER2319 and ER4043 welding wires reached up to 78% and 69%, respectively. Coarse dimples and voids had been observed in the fractographs. The joints showed a transgranular type failure.     

A study on shielding gas contamination in laser welding of non-ferrous alloys

Laser welding of non-ferrous alloys is a high-productivity and cost-effective joining technology, which gained an undoubted interest especially in aerospace, chemical and medical industry, where high strength and corrosion resistant mechanical parts are required. Unfortunately some of the most used non-ferrous alloys are highly reactive with respect to the components of the environmental atmosphere: oxygen, nitrogen, hydrogen and humidity. This reactivity leads to the formation of porosities and to oxides and nitrides inclusion, which are responsible for a decrease of ductility and strength in welded joints.According to this a good shielding technique of the weld pool is of primary importance in order to obtain sound beads and reliable manufacturings. This paper deals with the opportunity of simulating the shielding gas behavior by means of Computational Fluid Dynamics software in order to understand the relationship among the outlet position, the shielding gas type and its flow rate.A simulation activity was carried out in order to evaluate the behavior of shielding gas concentration surrounding the weld pool. The simulated welding environment was simplified without considering the presence and the effect of the plasma plume. The main results concern the shielding gas contamination prediction with respect to the distance from the beam-material interaction zone.     

Effect of CO2 shielding gas on metal droplet formationin arc welding

We have developed a unified arc electrode model that enables us to make predictions of the time development of molten drops from the welding wire in gas metal arc welding. The wire is taken as the positive electrode, and the effects of surface tension, magnetic pinch forces, and convection within the drop are taken into account to predict drop detachment for any given arc current. For pure argon, we have previously predicted the sharp transition that is observed experimentally at about 300 A between globular transfer at low current, when drop diameters are larger than the wire diameter, and spray transfer, for currents above 300 A, when drop diameters are smaller than the wire diameter. In this paper, we predict that addition of 25% of CO₂ to the argon leads to an increase in the transition current to more than 325 A, also in agreement with published experimental results. For pure CO₂, we find a significantly different drop behavior due to the more constricted arc. Both small and large drops are produced, with many very small drops being produced successively between each large drop     

Laser welding in a high pressure gas environment

A study was undertaken to investigate the effect of a high pressure gas environment on the laser welding mechanism. This was specifically related to high power CO₂ lasers in the power range between 1.2 and 5 kW. A small high pressure chamber rated up to 150 bar was utilized for the trials. Successful laser welding was completed up to a pressure of 50 bar in the pressurized helium environment. The chamber was modified to incorporate a high pressure transmissive zinc selenide window and internal focusing optics. The initial welds exhibited wide and shallow profiles indicating a loss of keyhole penetration welding. By filming the welding action the problem was found to be the formation of a plasma approximately an order of magnitude larger than in normal atmospheric conditions. The solution was to implement a gas jet system and to use a higher power laser. The resulting welds in terms of penetration and quality were significantly improved.     

5083铝合金光纤激光-TIG复合焊接工艺研究

采用IPG YLS-6000光纤激光器和Fronius MagicWave3000job数字化焊机,对4 mm厚5083 H116铝合金进行了复合焊接试验。研究了电源特性、电流大小和热源间距等工艺参数对光纤激光-钨极惰性气体保护焊（TIG）复合焊接焊缝成形的影响规律,并分析了焊接接头的缺陷、显微硬度及力学性能。结果表明,光纤激光-TIG复合焊接5083铝合金,能够明显改善焊缝成形,提高焊接过程稳定性,特别是与变极性TIG电弧复合效果更为显著;光纤激光与变极性TIG电弧复合焊接,采用激光在前的方式,电弧电流150 A,且热源间距不大于4 mm,可以得到具有明亮金属光泽和均匀鱼鳞纹的焊缝,焊缝无气孔和裂纹缺陷,其表面有少量的下凹;复合焊接接头抗拉强度为318 MPa,达到母材强度的93%,延伸率为7.6%,高于单光纤激光焊接,断口分析为韧性断裂。     

5083铝合金光纤激光-TIG复合焊接工艺研究

采用IPG YLS-6000光纤激光器和Fronius MagicWave3000job数字化焊机,对4mm厚5083H116铝合金进行了复合焊接试验。研究了电源特性、电流大小和热源间距等工艺参数对光纤激光-钨极惰性气体保护焊(TIG)复合焊接焊缝成形的影响规律,并分析了焊接接头的缺陷、显微硬度及力学性能。结果表明,光纤激光-TIG复合焊接5083铝合金,能够明显改善焊缝成形,提高焊接过程稳定性,特别是与变极性TIG电弧复合效果更为显著;光纤激光与变极性TIG电弧复合焊接,采用激光在前的方式,电弧电流150A,且热源间距不大于4mm,可以得到具有明亮金属光泽和均匀鱼鳞纹的焊缝,焊缝无气孔和裂纹缺陷,其表面有少量的下凹;复合焊接接头抗拉强度为318MPa,达到母材强度的93%,延伸率为7.6%,高于单光纤激光焊接,断口分析为韧性断裂。     

侧吹辅助气流对激光立焊5A90铝锂合金气孔影响

基于试验设计软件Design Expert V8设计试验,开展激光焊接5A90铝锂合金工艺试验,研究侧吹保护气流参数对焊缝气孔的影响规律,拟合侧吹流量、侧吹角度和等效气孔点数的函数图像,建立数学模型,优化保护气流参数,预测Ⅰ级焊缝保护气流参数范围。实验结果表明：侧吹气流的加入能明显抑制焊缝气孔,侧吹流量是显著因子,对气孔影响较大,随着流量的增加,气孔点数先增后减,在侧吹流量为5~7 L/min时有最小气孔点数;侧吹角度和交互项是不显著因子,在侧吹角度为20~30范围内,有一个较优值。气孔点数的最优响应模型为三阶模型,该模型拟合良好,经验证试验检验,模型误差范围小于10%,Ⅰ级焊缝易在侧吹流量为3~9 L/min,侧吹角度为15~52范围内获得。     

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.     

航天高压气体节流过程温变规律研究

基于焦-汤节流原理,针对航天领域常用气体在高压节流过程出现的温变现象,分析了高压气体节流温变过程及规律,开展了不同种类气体的节流温变对气体设备的影响研究。研究表明,对于预先压气的高压气瓶供气模式,氮气设备受节流降温影响较小,氧气设备则需关注节流元件及其下游设备对节流过程强烈降温效应的适应性;对于航天常用的液氮高压空浴汽化后在线压供气模式,为减少节流降温对下游设备的影响,需在高压空浴汽化器出口设置加温设施;对于高压氦气节流减压后的显著升温效应,为减少对下游设备的影响,采用液氮汽化对氦气进行降温是一种较为理想的技术路线。     

Approximate entropy a new statistic to quantify arc and welding process stability in short-circuiting gas metal arc welding

Based on the phase state reconstruction of welding current in short-circuiting gas metal arc welding using carbon dioxide as shielding gas, the approximate entropy of welding current as well as its standard deviation has been calculated and analysed to investigate their relation with the stability of electric arc and welding process. The extensive experimental and calculated results show that the approximate entropy of welding current is significantly and positively correlated with arc and welding process stability, whereas its standard deviation is correlated with them negatively. A larger approximate entropy and a smaller standard deviation imply a more stable arc and welding process, and vice versa. As a result, the approximate entropy of welding current promises well in assessing and quantifying the stability of electric arc and welding process in short-circuiting gas metal arc welding.     

液氮中单管加注二氧化碳气体的实验研究

向饱和液氮中加注常温二氧化碳气体时,为形成细小而分散的固体二氧化碳颗粒以及充分且均匀的固液混合物,通过实验分别采用不锈钢盘管、大管径塑料管以及金属毛细管往液氮中加注一定流量下的常温二氧化碳气体,研究固液混合过程、凝固颗粒大小以及管路的堵塞状况。结果表明,不管是否经过预冷,大直径管道加注时,经过一段时间后管道必定发生堵塞;而毛细管加注则不会堵塞,但是气体流量会发生脉冲性变化。     

The influence of process parameters on porosity formation in hybrid LASER-GMA welding of AA6082 aluminum alloy

This paper deals with an experimental campaign carried out on AA6082 8 mm thick plates in order to investigate the role of process parameters on porosity formation in hybrid LASER-GMA welding. Bead on plate weldments were obtained on the above mentioned aluminum alloy considering the variation of the following process parameters: GMAW current (120 and 180 A for short-arc mode, 90 and 130 A for pulsed-arc mode), arc transfer mode (short-arc and pulsed-arc) and mutual distance between arc and LASER sources (0, 3 and 6 mm). Porosities occurring in the fused zone were observed by means of X-ray inspection and measured exploiting an image analysis software. In order to understand the possible correlation between process parameters and porosity formation an analysis of variance statistical approach was exploited. The obtained results pointed out that GMAW current is significant on porosity formation, while the distance between the sources do not affect this aspect.     

Stability information in plasma image of high-power CO2 laser welding

In deep penetration laser welding, a capillary called keyhole is formed when the energy intensity reaches 10⁶ W/cm². During this process, the vaporized metal and the surrounding atmosphere can be ionized to form plasma both in and above the keyhole. The stability of the keyhole has an important influence on the properties of welded components and the fluctuations of plasma. In this paper, a method was developed to acquire the stability information from plasma images taken by high-speed photography. The influences of surface impurity and the flowrate of side-assist gas on the stability were investigated. Bead-on-plate welding was performed on 12 mm E-grade shipbuilding steel plates using a 15 kW CO₂ laser, with helium as the blowing gas. Three characteristic parameters were used to evaluate the stability. It was found that these three characteristic parameters can effectively indicate the stability variation caused by the surface impurity and gas flowrate. The present research provides important insights into developing image-based sensors to monitor the welding process.     

无阀微泵腔内气泡对周期驱动压力的影响

气泡的存在使无阀微泵的工作性能和使用寿命大大降低, 甚至无法正常工作. 为了合理地预测无阀微泵腔内气泡对周期驱动压力的影响, 给出了用来描述收缩管/扩张管型无阀压电微泵的数学模型, 包括泵腔体积变化、连续性方程、流体有效体积弹性模量以及锥管阻力系数的计算. 同时, 分析了腔内不同气泡体积对无阀微泵周期驱动压力的影响, 并对两个气泡进入无阀微泵泵腔时压力脉动过程进行了仿真和试验研究. 通过仿真结果与试验数据的比较表明, 所提出的存在气泡时无阀微泵数学模型及仿真方法是合理的. 关键词： 无阀微泵 气泡 压力脉动     

A hybrid unstable-waveguide resonator and output characteristics of a gap CO2-laser with high-frequency excitation

Experimentally and theoretically, we investigate the energy and spatial parameters of CO₂-laser generation with a gap active-medium geometry, high-frequency excitation, and an unstable-waveguide resonator. A generation power of 54 W is achieved in the continuous regime with the shape of the output radiation beam close to an axisymmetric one without resorting to external correcting optics. S. A. Esenin Ryazan State Pedagogical University, 46 Svoboda Str., Ryazan, 390000, Russia. Translated from Zhurnal Prikladnoi Spektroskopii, Vol. 66, No. 6, pp. 784–790, November–December, 1999.     

CO2-laser gas discharges in narrow gaps

We have studied RF discharges as excitation mechanisms for distributed feedback (DFB) CO₂ lasers. For CO₂ laser plasmas the reduced electric fieldE/N has to be in a well-defined range. The reduced electric fieldsE/N of gas discharges in the narrow gaps with widths of the order of 100 m required for DFB are considerably above this range. In order to study the feasibility of these RF-excited discharges for DFB CO₂ lasers we have measured the electron temperatureT _e in their plasmas. From helium-line-intensity ratios we have deduced a lower limit of the electron temperatureT _e of 4eV. The observed high intensities of bands of singly ionized nitrogen indicate an even higher electron temperature, but an efficient pumping of the upper laser level is not possible with an electron temperature above 2.5 eV.We have estimated the electron densityn _e and the current densityj _e from ratios of the intesities of forbidden and allowed helium lines. The high current densityj _e is in the range of abnormal glow discharges.In the gas discharges between narrow gaps the electron oscillation amplitudex _e is large than the electrode separationd. In order to replace the resulting high electron losses a high electron temperatureT _e is necessary to sustain the gas discharge. Because of this high electron temperatureT _e an efficient pumping of the upper laser level is not possible.     

A study of the shielding gas influence on the laser beam welding of AA5083 aluminium alloys by in-process spectroscopic investigation

In laser welding, the shielding gas is commonly used to stabilize the welding process, to improve welded joints features and to protect the welded seam against oxidization. Besides the type of shielding gas used, the nozzle parameters play an essential role. In fact, the chemical composition of the shielding gas and the flow geometry are key factors limiting the size of the plasma plume and its contamination by the surrounding atmosphere, and affecting the final quality of the welded joints.In this work, we present an experimental study on the complex physical phenomena occurring during the interaction between the plasma plume, the laser beam and the shielding gas by using an in-process spectroscopic investigation of the plasma plume characteristics under different operating conditions. A correlation was found between the spectral features and the formation of oxide layers on the surface of the welding seam, caused by defective gas shielding and by the vaporization of alloying elements. Experimental results have given useful indications for the development of innovative welding nozzle for application in laser welding of aluminium alloys.     

Effects of temperature-dependent material properties and shielding gas on molten pool formation during continuous laser welding of AZ91 magnesium alloy

Laser welding processes are widely used for fabrications in many engineering applications such as aerospace and automotives. In this paper, a moving distributed heat source model based on Goldak's method [1] has been implemented into finite volume thermal simulations in order to predict temperature distributions during the welding process of a magnesium alloy and to study the effects of variations in thermal properties, absorption coefficient and gas shielding on the computed temperature distributions and weld pool dimensions. The main conclusion is the significant effects of varying the thermal conductivity and absorption coefficient of magnesium. Also, it has been seen that the shielding gas, besides its main role of protection against oxidation, has a significant effect on the width of the weld pool. Finally, the obtained results have been compared to the experimental ones and a satisfactory correlation has been observed, indicating the reliability of the model developed in this study.