High-Speed X-Ray Analysis of Spatter Formation in Laser Welding of Copper

Heider, Andreas; Sollinger, J.; Abt, Felix; Boley, Meiko; Weber, Rudolf; Graf, Thomas

doi:10.1016/j.phpro.2013.03.058

Cited by 112 publications

(39 citation statements)

References 6 publications

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“…Therefore, the collaps of upper liquid titanium is an essential reason to form the spatter and pores. The collaps of liquid metal induces the spatter, which has observed via highspeed X-ray analysis during laser beam welding of the copper by A. Heider et al [29]. Laser keyhole welding for titaniumon-aluminum overlap configuration has bigger tendency of the collaps because the titanium has higher density and boiling point than that for the copper.…”

Section: Welding Spattermentioning

confidence: 96%

Laser penetration welding of an overlap titanium-on-aluminum configuration

Chen

Yang

et al. 2016

Int J Adv Manuf Technol

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An overlap titanium-on-aluminum configuration based on laser penetration welding was designed to suppress the formation of intermetallic compounds. Weld surface appearance, weldgeometry, microstructure, and mechanical property of the joint were investigated. The collaps of upper liquid titanium closes keyhole filled with boiling aluminum vapor, which induces welding spatter. Optimizing processing parameters could control the welding spatter to some extent. Weld geometry is characterized by depth of the weld loss, depth of the penetration of titanium into aluminum and width of joining, which depends on processing parameters strongly. The overlap titanium-on-aluminum configuration can suppress the formation of intermetallic compounds inside Ti weld. Interfacial reaction appears between Ti weld and Al, and the reaction layers are composed of TiAl and TiAl 3 . The banded structures with Ti 3 Al were found inside Ti weld. Tensile capacity of the joint increases firstly and then decreases with increasing laser power or decreasing welding speed, depending on weld geometry and interfacial reaction. Moreover, there are two broken modes of the joints, which are fractured in interface and in Ti weld, respectively. When joints fracture in the Ti weld, the joint has the higher tensile property, up to 184 N/mm.

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Section: Welding Spattermentioning

confidence: 96%

Laser penetration welding of an overlap titanium-on-aluminum configuration

Chen

Yang

et al. 2016

Int J Adv Manuf Technol

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“…The formation of melt ejections was examined by [10] using high-speed X-ray images. At the beginning of the welding process a narrow and straight keyhole is observed.…”

Section: Variable Methodsmentioning

confidence: 99%

“…An explanation can be derived from two publications. [8] explained the influence of the welding velocity on the formation of a vapor bubble, whereas [10] explains the rise of the melt ejection due to a vapor bubble. Based on these theories, melt ejections can only occur at a minimum welding depth.…”

Section: General Process Limitsmentioning

confidence: 99%

Laser Welding of Copper Using Multi Mode Fiber Lasers at Near Infrared Wavelength

et al. 2014

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Due to the increasing electrification of automotive drives and the expansion of decentralized renewable energy generation, the consumption of copper for the fabrication of electrical components such as electric motors or conducting paths increases. To join these components, laser welding is more frequently used since it represents a flexible and fully automatable joining process. Because of the high thermal conductivity, the low absorption coefficient for infrared wavelength of common laser beam sources and the resulting limited process efficiency, welding of copper alloys represents a major challenge for laser assisted processes. In this paper, experimental investigations are presented to identify arising process limits during laser welding of pure copper materials with multi-mode fiber lasers at near infrared wavelength depending on the applied laser power and welding velocity. In addition, a potential stabilization of the welding process by shielding gas support was examined. Further investigations were focused on the influence of shielding gas on the molten pool geometry.

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“…When the FPGA board detects the precursory phenomenon of weld spatter, by outputting a trigger signal, it is possible to force suppression control. The detailed and exact cause of the high intensity spots by the disturbance of the surface state is still unclear, but several theories exist; for example, a luminous body might occur with high luminance from the weld pool, such as a laser-induced plume or plasma, and gas bubbles (Chen, et al, 1996, Kang and Na, 2005, Schweier, et al, 2013, Heider, et al 2013). In any case, sensing the high-intensity spots is closely related to detecting signs of flying spatter.…”

Section: Generation Of the Histogrammentioning

confidence: 99%

Control system for reducing weld spatter during the welding process by using high-speed visual sensing

Sugawara

Kiyomitsu

Takano

et al. 2017

Mechanical Engineering Letters

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Robotic welding has been the biggest use in many industry. It is important to control weld robots without weld spatter for small size target. To prevent flying weld spatter, the precursory phenomenon of weld spatter must be detected, and power source of robotic welding must be controlled to reduce before weld spatter occurs. This study aimed to propose a control system to prevent the occurrence of flying weld spatter during laser or gas tungsten arc (GTA) welding process in real-time. Because the strategy involves detecting the precursory phenomenon at high-speed, we simplified the recognition system as much as possible. The system consists of a lighting system to illuminate the weld pool, a high-speed camera and an FPGA board. The control algorithm of this system used image data information for a histogram. We analyzed the images from the high-speed camera during welding. Our analysis found that, just before the weld spatter is generated, very bright pixels temporarily and abnormally increased as the precursory phenomenon. According to the proposed system, it is possible to prevent the occurrence of weld spattering in real time during the welding process. This integration of visual feedback in a robotic welding system enhances the quality of the weld work.

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High-Speed X-Ray Analysis of Spatter Formation in Laser Welding of Copper

Cited by 112 publications

References 6 publications

Laser penetration welding of an overlap titanium-on-aluminum configuration

Laser penetration welding of an overlap titanium-on-aluminum configuration

Laser Welding of Copper Using Multi Mode Fiber Lasers at Near Infrared Wavelength

Control system for reducing weld spatter during the welding process by using high-speed visual sensing

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