Investigations on the occurrence of different wetting regimes in laser brazing of zinc-coated steel sheets

Abstract

In the automotive industry, the seam edge quality of laser brazed seams is a crucial factor for the required high optical quality standards of customer-visible connections of zinc-coated car body parts. The type of zinc coating is decisive for the resulting geometry of the seam edges, which are aspired to be straight. Especially brazing of hot-dip galvanised steel with conventional brazing setup is not resulting in seam edges which fulfil the required optical quality. In this study, the wetting of copper-based filler wire on electrogalvanised and hot-dip galvanised steel sheets is analysed to increase the understanding of the influence of the wetting fronts on the seam edge quality. For this, the wetting fronts are determined in high-speed camera images and the resulting seam edges are captured by microscopic pictures. The results show that two major wetting regimes occur on both types of zinc coatings but with a different occurrence probability: one with a steep wetting front and zinc evaporation in front of wetting ("steep-angle-wetting") and one where liquid zinc connects with the wetting front and creates a flat wetting angle ("flat-anglewetting"). It is found that the resulting seam edge quality is mainly depending on the present wetting regime. However, for flatangle-wetting, in the regime with insufficient seam edge quality, a self-stabilising effect is identified, which is responsible for a missing process window for brazing of hot-dip galvanised steel with sufficient seam edge quality.

The influence of the ratio between the wire and process velocities on the wetting process during laser brazing

“…To ensure optical seam quality, the wetting process in laser brazing is of major importance [9]. As an example, the mechanism of pore formation is described by Frank et al as the formation of constrictions in the area of the wetting front as a consequence of a temporary interruption of the wire feed [10].…”