For a long time, laser welding and arc welding have their own special application fields due to the different physical processes of energy transmission and the way energy flows. The laser-welded process has a very narrow heat-affected zone, and the weld has a high aspect ratio and a high welding speed. However, due to the small focal diameter, the weld bridging ability is poor. The arc welding process has a low energy density, but can form a large focus point on the surface, and the disadvantage is that the process speed is slow.
If you combine these two processes, what will happen? It has been proved that the hybrid welding process of the two processes can obtain a very good comprehensive effect, and has obvious advantages in welding quality, production engineering and production cost, and thus has been widely used in the automobile industry.
Development
As early as the 1970s, the method of combining the laser beam and the welding arc to form a welding process was known, but for a long time, no further development of this process was carried out. However, researchers have recently turned their attention to this process, trying to combine the advantages of arc welding with the advantages of laser welding to form a hybrid welding process.
In the early days, the suitability of lasers for industrial use has yet to be proven, and today, in many manufacturing companies, lasers have become almost a standard device. Combining the laser welding process with another welding process is called "laser hybrid welding process", that is, the laser beam and the arc act simultaneously in one welding area, and the two influence each other and support each other.
Laser welding requires not only powerful laser power, but also a high-quality laser beam to achieve the desired "deep weld effect." For example, Volkswagen's current project uses a lamp-pumped solid-state laser with a laser beam of 4 kW. The laser is transmitted through water-cooled 600 mm glass fiber. The laser beam is projected onto the workpiece to be welded by a focusing module with a focal length of 200 mm/220 mm. on.
The laser arc hybrid welding process combines the two welding processes of laser welding and arc welding to obtain excellent comprehensive performance and improve efficiency/cost ratio. For example, the welding speed of laser welding of 1.5mm+2.0mm AlMgSi1 joint can reach 8.1m/min, and only 4kW solid laser source is needed.
When the metal workpiece is welded by the laser hybrid welding process, the yttrium aluminum garnet laser beam is focused to obtain a beam of 106 W/mm2 intensity. When the laser beam hits the surface of the material, the irradiation point is heated to the vaporization temperature. Due to the escape of the vaporized metal, a vaporization cavity is formed on the weld metal. The weld joint is characterized by a very high aspect ratio, free-burning arc. The energy flow density is slightly higher than 104 W/mm2. In addition to the heat from the arc, the laser beam transfers heat to the weld metal at the top of the joint. Different from the sequential configuration of two different welding processes, the hybrid welding process can be seen as a combination of two welding processes and simultaneously work in the same process area. Depending on the type of arc or laser process used and the process parameters, the degree of interaction between processes varies and the way in which they occur is different.
Combining the laser with the arc increases the weld penetration depth and weld speed compared to using the two processes separately. The metal vapor escaping from the steam cavity interacts with the arc plasma, and the amount of yttrium aluminum garnet laser radiation absorbed into the process plasma is negligible. Depending on the power input ratio of the two processes, the overall process characteristics are primarily determined by the laser or arc. The surface temperature of the workpiece has a substantial effect on the absorption of the laser radiation. Prior to the start of the laser process, the initial reflections must be overcome, especially on the surface of the aluminum, and the special start-up procedure is used to initiate the weld, which can overcome the initial reflection. After the vaporization temperature is reached, a vaporization cavity is formed, at which point almost all of the radiant energy can act on the workpiece, and the energy required depends on the temperature-dependent absorption and the amount of energy lost by conduction to the rest of the workpiece. . In the hybrid welding process, vaporization occurs not only on the surface of the workpiece, but also on the wire, so that more metal vapor can be obtained, which in turn facilitates the input of laser radiation and prevents the degradation of process parameters.
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