Visualization and quantification of melt flow dynamics for laser welding with superimposed intensity distributions analyzed by synchrotron radiation imaging
摘要
Modern solid-state lasers enable a continuous increase in welding speed due to higher possible laser beam powers. However, welding speeds above 8 m/min for high-alloy steels lead to altered melt flow dynamics and increased spatter formation, resulting in spatter adhesion and particularly in undercuts along the weld seam. In contrast to the cost- or time-intensive methods described in the state of the art to reduce these effects, modifying the intensity distributions appears to be a simple and effective approach that is independent of the welding direction. In particular, using a superimposed intensity allows a detailed investigation by adjusting the intensity with varying spot sizes or laser powers. Using a superimposed intensity to widen up the melt pool is especially effective in reducing the velocity of the melt flow around the keyhole and, consequently, spatter formation. However, its effect on other melt pool flows, especially the upward directed melt flow along the keyhole rear wall, remains largely unknown. To investigate these effects, high-speed synchrotron X-ray imaging in combination with tungsten carbide tracer particles was used to visualize the melt flow dynamics. Generally, two melt vortices are observed in the area behind the keyhole, one in the upper and one in the lower part of the melt pool. The backward melt flow at the melt pool bottom is unaffected by the additional energy input due to the limited penetration depth of the second laser. Furthermore, the upward directed flow along the keyhole rear wall remains unchanged. When increasing the second laser power, the keyhole widens and fluctuates at the rear wall. As a result, the upward melt flow at the rear wall is not discernible. In general, the superimposed intensity alters the melt flow behind the keyhole. However, these changes appear to be minor significant for spatter formation compared to the flow around the keyhole.