Spatter formation is a major issue in deep penetration welding with solid state lasers at high welding speeds from 8 up to 20 m/min. One approach to describe spatter formation is based on the assumption of an unstable keyhole. This leads to a temporary constriction of the keyhole due to the melt pool whereby the keyhole pressure increases. Finally, the keyhole collapses and spattering occurs. Therefore, the stabilization of the capillary is a possible way to limit spatter formation. For this purpose, several potential solutions have been tested in the past. However, investigations regarding a precisely local adjustable shielding gas flow on the keyhole stability under the condition of high welding speeds (≥ 8 m/min) is not given in the state of the art yet. To investigate these interactions, a shielding gas supply was developed, which can be adjusted in four axes with a reproducibility of 0.02 mm. Furthermore, the assembly was provided with a coaxial alignment laser for determining the interaction region of the gas. Under the processing of stainless steel (1.4301), different flow rates of argon, helium and nitrogen were tested. Additionally, Schlieren videography was used to visualize the gas flow. The spatial orientation has been varied in angles from 20° up to 48°. The experiments were recorded by means of HV-camera and subsequently analyzed by image processing (number, velocity and trajectory of spatters). Thereby, it was possible to reduce spattering by up to 91 % at welding speeds of up to 16 m/min.
This paper investigates laser welding of AA 6082 by superimposing a pulsed Nd:YAG laser with a continuous wave diode laser in order to reduce the hot-cracking susceptibility. Conventional pulsed laser welds exhibit severe solidification cracking on the application of a conventional rectangular laser pulse shape. Through the superposition of a Nd:YAG and diode laser beam crack-free welds can be realized without the use of an additional filler material in the case of sheet thickness of 0.5 mm. The diode laser beam simultaneously heats the base metal and weld metal during the melt-pool solidification and compensates solidification shrinkage and thermal contraction. Furthermore, the superimposed diode laser reduces the cooling rate during the melt-pool solidification. Hot-cracking can be eliminated by using an additional diode laser with a low output power of approximately 300W. A major impact of the diode laser superposition on the hot-crack suppression is expected to be achieved by reducing the solidification rate during the melt-pool solidification. These thermal changes result in coarser microstructure and therefore enable the easier feeding of liquid into the interdendritic cavities.
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