Spatter formation in laser beam welding using laser beam oscillation

Hugger, Florian; Hofmann, Konstantin; Kohl, Stefanie; Dobler, Michael; Schmidt, Michael

doi:10.1007/s40194-014-0189-9

Cited by 39 publications

(6 citation statements)

References 4 publications

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“…The observations of a chaotic melt pool surface with the visual appearance of the weld bead geometry correlate with this statement. Excessive spatter behavior has also been reported by [3].…”

Section: Discussionmentioning

confidence: 80%

“…Excessive spatter generation and dynamic process behavior are especially observable in the laser keyhole welding of aluminum alloys containing elements with low boiling temperatures [3]. As one of these, magnesium has a high evaporation rate due to its high thermodynamic activity and low vaporization temperature in comparison to pure aluminum (a difference of 1360 K).…”

Section: State Of Researchmentioning

confidence: 99%

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Influence of Magnesium on Spatter Behavior in Laser Deep Penetration Welding of Aluminum Alloys

Felsing

Woizeschke

2019

JMMP

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The quality of welds, as well as the necessity of post-processing, is challenged by spatter generation during the laser keyhole welding process. In this study, the influence of the magnesium content on spatter behavior is studied for three aluminum alloys (Al99.5, AlMg3, and AlMg5). A synchronized dual high-speed camera system is used to observe the spatter behavior and to reconstruct 3D spatter trajectories as well as determine the characteristics of spatter velocity, flight path angle, and approximate spatter size. The mean spatter velocities and flight path angles of the welding experiments with the three alloys were in welding direction between 4.1 m/s and 4.6 m/s and 44.8° and 51.0°, respectively. Furthermore, the AlMg alloys show excessive spatter behavior with spray events of more than 50 spatters at a time, and less frequently spatter explosions. Spatter spray events show a character similar to spatter explosions. Volumetric evaporation is proposed as effecting these events. In contrast, and resulting from a different mechanism, pure aluminum (Al99.5) shows group ejection events with at least 10 spatters at a time. In this study, there are no correlations between spatter velocities and flight path angles, nor between velocities and approximate spatter sizes.

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Section: Discussionmentioning

confidence: 80%

Section: State Of Researchmentioning

confidence: 99%

Influence of Magnesium on Spatter Behavior in Laser Deep Penetration Welding of Aluminum Alloys

Felsing

Woizeschke

2019

JMMP

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“…The Gaussian distribution is one of the most frequent methods to describe the continuous heat distribution from the laser beam [32]. The newly developed RLW process with an oscillating beam improves strength, reduces spatter formation, and stabilises the process [33,34]. It has also been found to improve the gap bridging ability for imperfect edges due to wider welds in tailored blanks [35] in addition to enhancing joint quality by increasing the bond area [36].…”

Section: Introductionmentioning

confidence: 99%

Numerical modelling of thermal quantities for improving remote laser welding process capability space with consideration to beam oscillation

Mohan

Ceglarek

Auinger

2022

Int J Adv Manuf Technol

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This research aims to explore the impact of welding process parameters and beam oscillation on weld thermal cycle during laser welding. A three-dimensional heat transfer model is developed to simulate the welding process, based on finite element method. The results obtained from the model pertaining to thermal cycle and weld morphology are in good agreement with experimental results found in the literature. The developed heat transfer model can quantify the effect of welding process parameters (i.e. heat source power, welding speed, radius of oscillation, and frequecy of oscillation) on the intermediate performance indicators (IPIs) (i.e. peak temperature, heat-affected zone (HAZ) volume, and cooling rate). Parametric contour maps for peak temperature, HAZ volume, and cooling rate are developed for the estimation of the process capability space. An integrated approach for rapid process assessment, and process capability space refinement, based on IPIs is proposed. The process capability space will guide the identification of the initial welding process parameters window and helps in reducing the number of experiments required by refining the process parameters based on the interactions with the IPIs. Among the IPIs, the peak temperature indicates the mode of welding while the HAZ volume and cooling rate represent weld quality. The regression relationship between the welding process parameters and the IPIs is established for quick estimation of IPIs to replace time-consuming numerical simulations. The application of beam oscillation widens the process capability space, making the process parameter selection more flexible due to the increase in distance from the tolerance boundaries.

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“…New data suggests that the pool does not come in contact with the powder layer, and individual powder particles enter it together with the surrounding gas flow formed around the evaporation jet. Existing works on the visualization of the jet are limited by the use of a high-speed camera and a magnifying lens, which allows only considering in detail, the molten pool and the thermal radiation of the plume [5,8,[16][17][18][19]. These works also reported that the resulting gas-vapor jet is not limited only to the zone of its own radiation, but also determines the zones of high and low pressure.…”

Section: Introductionmentioning

confidence: 99%

Interferometry of Gas-Phase Flows during Selective Laser Melting

et al. 2019

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Gas-phase flows occurring in a plume in a processing zone during selective laser melting (SLM) can significantly affect the quality of the process. To further enhance SLM performance, the characteristics of the flows should be considered. In this article, the vapor-gas jet emerging from the laser processing zone was studied. It was visualized by interferometry to evaluate flow velocity, geometry and changes in refractory index depending on laser power. The velocity and pressure fields of the vapor jet and the entrained ambient gas were estimated by mathematical modeling. It was shown that the increase of laser power led to higher jet velocity and greater change in its refractory index. The latter also was used to evaluate the content of metal vapor in the plume and its influence on the absorption of laser radiation.

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Spatter formation in laser beam welding using laser beam oscillation

Cited by 39 publications

References 4 publications

Influence of Magnesium on Spatter Behavior in Laser Deep Penetration Welding of Aluminum Alloys

Influence of Magnesium on Spatter Behavior in Laser Deep Penetration Welding of Aluminum Alloys

Numerical modelling of thermal quantities for improving remote laser welding process capability space with consideration to beam oscillation

Interferometry of Gas-Phase Flows during Selective Laser Melting

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