Scholarlink

<p>The high energy consumption and low efficiency of laser welding have long been a significant environmental concern in reducing energy consumption and emissions. Many quantitative approaches have been adopted in evaluating the energy consumed in the manufacturing process, but the relationship between laser welding process parameters and energy consumption has still not been revealed. This study innovatively proposed a melting volume specific energy consumption (MVSEC) mechanism model based on the physical properties of energy conversion and transfer to quantitatively evaluate the energy efficiency at process level. This model combined wire preheating energy and laser energy to correlate the preheating temperature (T) with the wire melting volume (V). A dedicated preheating temperature model was established under the assumption of wire material, temperature distribution and thermal radiation coefficient. A novel trace element method that precisely determines the fusion zone boundary was developed by analyzing the distribution of specific trace elements (Ni) between the welding wire and base material. The experiment verification employed wire endpoint preheating temperature measurement and hot-wire laser welding of double-galvanized high-strength steel DP800, demonstrating the accuracy of the preheating temperature model. The MVSEC model exhibited an average relative error of 6.2%. Further analysis was conducted on the MVSEC and energy saving ratio under different wire feeding parameters, wire endpoint preheating temperatures, butt gaps and fusion ratios. The results demonstrate that, compared with cold wire welding, under the optimized process parameters (600 ~ 800&#xa0;°C preheating temperature, 0.6&#xa0;mm butt gap and 0.46 fusion ratio), the minimum specific energy consumption achieved was 40.1&#xa0;J/mm³, and the hot-wire process achieves energy savings of 10.3–14.1%. The research work provides a foundation for optimizing laser welding processes and establishing standardized assessments of energy consumption and efficiency.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Mechanistic model for estimating specific energy consumption and efficiency of hot-wire laser welding process

  • 期刊论文

  • 发表日期：

    2026年1月19日

查看全文
  • Haiying Wei,
  • Songjun Wang,
  • Fengbo Yuan

摘要

The high energy consumption and low efficiency of laser welding have long been a significant environmental concern in reducing energy consumption and emissions. Many quantitative approaches have been adopted in evaluating the energy consumed in the manufacturing process, but the relationship between laser welding process parameters and energy consumption has still not been revealed. This study innovatively proposed a melting volume specific energy consumption (MVSEC) mechanism model based on the physical properties of energy conversion and transfer to quantitatively evaluate the energy efficiency at process level. This model combined wire preheating energy and laser energy to correlate the preheating temperature (T) with the wire melting volume (V). A dedicated preheating temperature model was established under the assumption of wire material, temperature distribution and thermal radiation coefficient. A novel trace element method that precisely determines the fusion zone boundary was developed by analyzing the distribution of specific trace elements (Ni) between the welding wire and base material. The experiment verification employed wire endpoint preheating temperature measurement and hot-wire laser welding of double-galvanized high-strength steel DP800, demonstrating the accuracy of the preheating temperature model. The MVSEC model exhibited an average relative error of 6.2%. Further analysis was conducted on the MVSEC and energy saving ratio under different wire feeding parameters, wire endpoint preheating temperatures, butt gaps and fusion ratios. The results demonstrate that, compared with cold wire welding, under the optimized process parameters (600 ~ 800 °C preheating temperature, 0.6 mm butt gap and 0.46 fusion ratio), the minimum specific energy consumption achieved was 40.1 J/mm³, and the hot-wire process achieves energy savings of 10.3–14.1%. The research work provides a foundation for optimizing laser welding processes and establishing standardized assessments of energy consumption and efficiency.