Influence of laser power on molten pool flow field of laser-MIG hybrid welded Invar alloy

Yan, Tingyan; Zhan, Xiaoli; Gao, Qingji; Wang, Feiyun; Ling, Wanli

doi:10.1016/j.optlastec.2020.106539

Cited by 23 publications

(10 citation statements)

References 30 publications

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“…As the laser power increases to 8 kW, the workpiece is collapsed, the melt pool energy continues to move down to the collapsed area, and the loss of laser energy causes the melt pool temperature to decrease. Since the main driving force for keyhole formation is the recoil pressure of the metal vapor generated by the high-energy-density laser, the laser power is the key factor affecting the lock hole depth [29]. Figure 12 shows the evolution of the keyhole at a laser power of 7.5 kW.…”

Section: Resultsmentioning

confidence: 99%

“…The multiple reflections of the laser in the keyhole promote the absorption of the laser by the keyhole. With the increase of laser power, the depth of the keyhole increases, the laser energy is delivered to the deeper layer of the workpiece, and the melt pool depth increases [29]. Figure 14 shows the variation of the molten pool depth below the keyhole w for three laser powers.…”

Section: Resultsmentioning

confidence: 99%

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Effect of Weld Pool Flow and Keyhole Formation on Weld Penetration in Laser-MIG Hybrid Welding within a Sensitive Laser Power Range

Jing

Hou

et al. 2022

Applied Sciences

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The weld penetration variation in laser-MIG hybrid welding under sensitive laser power range was investigated by welding experiments and CFD (computational fluid dynamics) simulation. During this investigation, joints of AH36 sheets were welded with varying laser powers by the laser-MIG hybrid welding process. In addition, the CFD model was established based on experimental parameters and measurement results. Moreover, surface tension, electromagnetic force, buoyancy, recoil pressure, evaporative condensation, evaporative heat exchange, melt drop transfer, and other factors were considered. The influence of various factors on molten pool depth and keyhole depth were studied, including temperature, velocity, and flow direction of liquid metal. The results show that the weld-forming effect is better at the laser power is 7.5 kW in the range of sensitive laser power. After the keyhole is formed, its depth gradually entered the stage of linear increase, oscillation increase, and oscillation balance. Increasing the laser power can effectively shorten the time of the two growth stages and allow the keyhole to enter the balance stage earlier. During the oscillation balance state of the keyhole, the molten metal under the keyhole flowed to the molten pool root in the reverse direction of welding; it can also promote weld penetration.

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Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%

Effect of Weld Pool Flow and Keyhole Formation on Weld Penetration in Laser-MIG Hybrid Welding within a Sensitive Laser Power Range

Jing

Hou

et al. 2022

Applied Sciences

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“…Therefore, it can be said that the HFSC technique combines the best of FSC and FSW processes, in a distinct single processing action with its own challenges, namely including parameters inherent to the integration of the integrated actions of channeling and welding, just like in other hybrid solutions such as laser-MIG hybrid welding integrating different power sources. [63] HFSC opens a new dimension in engineering design for thermal management, by using channels in lightweight materials, such as aluminum alloys, that can be used as small width and thick ribs, welded to thin and large width sheet metal of high density and expensive materials with high thermal performance, such as Cu and its alloys, as depicted in Figure 8b. Wherein combination of Al-Cu system enhances heat extraction capacity and reduces overall weight.…”

Section: Hybrid Friction Stir Channelingmentioning

confidence: 99%

“…Therefore, the retreating side of Figure 22. Microstructures of hybrid friction stir channeling (HFSC) (a) ceiling zone, [63] (b) weld zone, [63] (c) weld zone-hook like effect [51] and (d) weld zone-film like flaws. [51] Figure 23.…”

Section: Surface Features and Performancementioning

confidence: 99%

A review on friction stir-based channeling

Mehta

Vilaça

2021

Critical Reviews in Solid State and Materials Sciences

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Friction stir-based channeling is a solid-state processing encompassing the friction stir channeling (FSC) and its variants. In one manufacturing action, the FSC delivers a subsurface internal closed channel in a monolithic plate with no length limitation. The unique characteristics of theses internally closed channels produced with FSC can fit the demand from several industrial fields, namely lightweight structurally stiffened panels and applications where high power density requires highly efficient thermal management systems, such as power electronics and electric vehicles-based transportation. This first review on the FSC and its variants encompasses a systematic and comprehensive understanding on physical properties, including thermal performance and channel manufacturability applied to different engineering materials. The discussion is emphasized on working principle of channel formation, tool design, influence of process parameters, geometrical characterization, mechanical properties, hardness field and microstructural features correlated with mechanical properties. It can be summarized that novel processing of channels by FSC enhances the thermal performance compared to conventional fabrication techniques. FSC can produce complex path channels with various sizes, shapes and surface finishing. Precise control on process parameters and material flow governs the channel formation that subsequently influences thermal and mechanical performances of the channels. FSC has been applied to different range of thermal management systems and has potential for many demanding existent applications and enabling new high-performance products. From the initial FSC concept based on a shoulder-workpiece clearance, to the most recent solutions, such as the stationary shoulder FSC, and the no-tilt-angle and no-shoulder-workpiece clearance, allowing the manufacturing of large size channels, leaving the processed surface at its original quota and ready to be used. A significant leap is introduced with the Hybrid FSC enabling simultaneous welding and channeling, of similar and dissimilar metal components, and therefore, enhancing design opportunities for even more competitive solutions.

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“…The wide process window with laser spot diameter of 360 or 560 μ m and welding speed of 4.5∼10 m/min can produce undercharge or hump. Yan et al 17 found that the depth of keyhole was mostly impacted by the laser power. And the increase of laser power was beneficial to obtain weld seam with larger depth-to-width ratio.…”

Section: Introductionmentioning

confidence: 99%

Study on molten pool dynamics and hump formation mechanism in laser wire feeding additive manufacturing

Peng

Zheng

Huang

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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The mechanism of the hump formation during the laser wire feeding process has been investigated in this paper. A numerical model was established to analyze the heat transfer and melt flow of molten pool during process with or without hump formation. And effects of laser power, traverse speed, and wire feeding speed on hump formation were also investigated through such a numerical model. The results showed that, under the condition with high wire feeding speed, the molten metal flowed rapidly to the tail of the molten pool due to the impact force of droplet and the metal vapor recoil pressure. Simultaneously, due to the high speed of laser movement, the thin channel of the trough solidified prematurely under the effect of surface tension, which isolated the heat transfer of the molten pool, and then formed periodic humps. By comparative analysis, the numerical simulation results were in good agreement with the experimental results.

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Influence of laser power on molten pool flow field of laser-MIG hybrid welded Invar alloy

Cited by 23 publications

References 30 publications

Effect of Weld Pool Flow and Keyhole Formation on Weld Penetration in Laser-MIG Hybrid Welding within a Sensitive Laser Power Range

Effect of Weld Pool Flow and Keyhole Formation on Weld Penetration in Laser-MIG Hybrid Welding within a Sensitive Laser Power Range

A review on friction stir-based channeling

Study on molten pool dynamics and hump formation mechanism in laser wire feeding additive manufacturing

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