Monitoring of keyhole entrance and molten pool with quality analysis during adjustable ring mode laser welding

Wang, Lin; Mohammadpour, Masoud; Yang, Baixuan; Gao, Xiangdong; Lavoie, Jean-Philippe; Kleine, Klaus; Kong, Fang; Kovacevic, Radovan

doi:10.1364/ao.383232

Cited by 47 publications

(8 citation statements)

References 23 publications

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“…The inner core promotes the generation of the keyhole, while the ring-shaped laser beam allows controlling the distribution of temperature and cooling rate in and around the molten pool. Research has confirmed a positive effect of ARM laser on keyhole stabilization [15]. The stability of the keyhole and, therefore, of the welding process is a vital indicator of the weld quality in those applications where partial penetration is required, such as welding of battery tab connectors.…”

Section: Introductionmentioning

confidence: 93%

Applying optical coherence tomography for weld depth monitoring in remote laser welding of automotive battery tab connectors

Соколов

Franciosa

Sun

et al. 2020

Journal of Laser Applications

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This paper addresses in-process monitoring of weld penetration depth (WPD) during remote laser welding of battery tab connectors using Optical Coherence Tomography (OCT). The research aims at studying the impact of welding process parameters on the accuracy of WPD measurements. In general, the highest measurement accuracy is achievable by positioning the OCT measuring beam towards the bottom of the keyhole. However, finding and maintaining the alignment between the OCT measuring beam and the bottom of the keyhole is a challenging task because of the dynamic changes in size and shape of the keyhole itself.The paper addresses the above challenge by (1) developing welding process parameters for Al-Cu thin foil lap joint (Al 1050 foil 450 μm and Ni-plated Cu foil 300 μm) using novel Adjustable Ring Mode (ARM) laser; and, (2) integrating OCT technology with two beams: one targeting the bottom of the keyhole and another as a reference to the part surface (TwinTec technology). The methodology is underpinned by the "Keyhole Mapping" approach which helps to identify the optimal placement of the OCT measuring beam with considerations to both measurement accuracy and stability of the keyhole.Findings indicated that welding with the ARM laser results in more stable process, reduces fluctuations of keyhole opening and, therefore, helps to improve the measurement accuracy by a factor of 50% (from average error of 0.22 mm to 0.11 mm). Results further identified that the feasible operating window of the OCT measuring beam, corresponding to the highest measurement accuracy, is below 20 μm in length.

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Section: Introductionmentioning

confidence: 93%

Applying optical coherence tomography for weld depth monitoring in remote laser welding of automotive battery tab connectors

Соколов

Franciosa

Sun

et al. 2020

Journal of Laser Applications

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“…The separator, which was heated to more than 160ºC, shrank horizontally, causing a short circuit due to direct contact of the cathode material and anode material. 4) Continued laser irradiation produced a molten pool (9) . The molten pool contributed to stable heating of these areas, expanding the short circuit area.…”

Section: Estimated Process Of Thermal Runaway Caused By Lasermentioning

confidence: 99%

Demonstrating Thermal Propagation Test for Battery Pack for PHEV with Laser Irradiation as Initiation Method

Koshika

Kagei

Tsuruga³

et al. 2022

IJAE

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The use of laser irradiation for heating is characterized by localized heating and high power density heating, which make the method suitable for conducting thermal propagation tests for battery packs for electrified vehicles. This paper demonstrates a thermal propagation test for battery packs for PHEVs using laser irradiation. It describes one example of the practicality of using laser irradiation as an initiation method for thermal propagation tests for large battery packs for electrified vehicles. One of the advantages of laser irradiation, which is that thermal runaway occurs with minimal heating of adjacent cells, was confirmed to be maintained for the pack level test.

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“…In addition to ordinary monitoring sensors, some special technologies can be used, such as on-line coherent imaging [60], X-ray diffractometer [61] and Hanover analyzer [62]. From the current research, the detection of laser welding process signal mainly focuses on sound, light, electricity and heat [63][64][65][66][67][68][69][70][71].…”

Section: Single Signal Monitoringmentioning

confidence: 99%

Innovations in Monitoring, Control and Design of Laser and Laser-Arc Hybrid Welding Processes

Cheng

Ning

et al. 2021

Metals

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With the rapid development of high power laser, laser welding has been widely used in many fields including manufacturing, metallurgy, automobile, biomedicine, electronics, aerospace etc. Because of its outstanding advantages, such as high energy density, small weld size, easy automation. Combining the two heat sources of laser and arc for welding can achieve excellent results due to the synergistic effect. Laser welding is a complicated physical and chemical metallurgical process, involving the laser beam and molten pool, keyholes and materials melting, evaporation and multiple physical process. Process monitoring and quality control are important content of research and development in the field of laser welding, which is the premise to obtain fine weld with high quality. Numerical simulation technology can describe many complex physical phenomena in welding process, which is very important to predict weld forming and quality and clarify the underline mechanism. In this paper, the research progress of process monitoring, quality control and autonomous intelligent design of laser and laser-arc hybrid welding based on numerical simulation were reviewed, and the research hotspots and development trends of laser welding in the future are predicted.

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Monitoring of keyhole entrance and molten pool with quality analysis during adjustable ring mode laser welding

Cited by 47 publications

References 23 publications

Applying optical coherence tomography for weld depth monitoring in remote laser welding of automotive battery tab connectors

Applying optical coherence tomography for weld depth monitoring in remote laser welding of automotive battery tab connectors

Demonstrating Thermal Propagation Test for Battery Pack for PHEV with Laser Irradiation as Initiation Method

Innovations in Monitoring, Control and Design of Laser and Laser-Arc Hybrid Welding Processes

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