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<p>This research delves into the intricate melt flow dynamics observed in asymmetric stainless steel 316L T-joints with dual-beam laser welding, with a particular focus on configurations involving sheets inclined at angles up to 45°. Given the complexity of this welding scenario, the use of filler wire is necessitated, which is only accessible from the top side in this case. To capture the transient melt pool phenomena high-speed imaging techniques (HSI) were employed at both the top and root of the weld. Through HSI observations along with streak analysis, three primary mechanisms were identified: Atypical-flow connection-root and top side, atypical-flow connection-top side and typical-flow disconnection-root side<i>.</i> These observations highlight several critical factors, at the top and bottom of the weld, including intermittent keyhole openings, transient melt flow effects, potential spatter ejection, reabsorption, pronounced bulge and disintegration. These phenomena collectively contribute to weld imperfections, revealing impacts on meandering root and craters. The study provides a comprehensive understanding of 3D asymmetric melt flow dynamics. By categorizing the observed mechanisms, this research is theoretically described and formulated in a systematic flowchart, for laser welding of an asymmetric T-joint.</p>

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Melt flow mechanisms in dual-spot laser welding of asymmetric T-joints with wire feed

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年5月13日

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  • Dorsa Motalebi,
  • Alexander F. H. Kaplan

摘要

This research delves into the intricate melt flow dynamics observed in asymmetric stainless steel 316L T-joints with dual-beam laser welding, with a particular focus on configurations involving sheets inclined at angles up to 45°. Given the complexity of this welding scenario, the use of filler wire is necessitated, which is only accessible from the top side in this case. To capture the transient melt pool phenomena high-speed imaging techniques (HSI) were employed at both the top and root of the weld. Through HSI observations along with streak analysis, three primary mechanisms were identified: Atypical-flow connection-root and top side, atypical-flow connection-top side and typical-flow disconnection-root side. These observations highlight several critical factors, at the top and bottom of the weld, including intermittent keyhole openings, transient melt flow effects, potential spatter ejection, reabsorption, pronounced bulge and disintegration. These phenomena collectively contribute to weld imperfections, revealing impacts on meandering root and craters. The study provides a comprehensive understanding of 3D asymmetric melt flow dynamics. By categorizing the observed mechanisms, this research is theoretically described and formulated in a systematic flowchart, for laser welding of an asymmetric T-joint.