Research Status of Stability in Dynamic Process of Laser-Arc Hybrid Welding Based on Droplet Transfer Behavior: A Review

Liu, Qingyong; Wu, Di; Wang, Qingzhao; Zhang, Peilei; Yan, Hua; Sun, Tianzhu; Zeng, Jie; Yan, Ming; Liu, Zhenyu; Li, Ruifeng

doi:10.3390/coatings13010205

Cited by 10 publications

(2 citation statements)

References 113 publications

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“…In contrast to MAG welding, the hybrid Laser-MAG process combines the merits of both arc and laser, representing an innovative type of welding heat source. It has the advantages of high welding speed, strong bridging capacity, ability to adapt to large clearance, and large weld melting depth [8], [9], which contribute to its excellent application prospects in the field of automobile manufacturing.…”

Section: Introductionmentioning

confidence: 99%

An improved simulation of temperature field in Laser–low current

Xu,

Sun,

Han

et al. 2024

Preprint

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This study aimed to achieve efficient and precise connection of thin steel sheets for vehicles by analyzing the thermal process of Laser-MAG hybrid high-speed welding lap of thin galvanized steel sheets. A high-speed camera combined with an NI AD data acquisition system were used, and the transition behavior and electrical signals of low-current MAG and Laser-MAG hybrid welding were examined. The thin sheet MAG welding droplet transition method mainly comprised short-circuit transfer. During the short-circuit phase, the voltage decreased and the current increased sharply, forming a short-circuit liquid column. When current increased to a certain level, the liquid bridge burst, the droplets carried heat and kinetic energy to the weld pool, the arc voltage returned to a no-load state, and the arc was re-ignited. In the arcing phase, the current first decreased steeply and then slowly, while the voltage decreased slowly and smoothly. According to the different heat source characteristics of the arc combustion and short-circuit stages during short-circuit transition, a new MAG heat source for low-current short-circuit transition was developed. This study employed a double-ellipse heat source with different powers for the arc combustion stage as well as a uniform body heat source that considered the thermal and kinetic energies of the melt droplets for the short-circuit stage. The thermal input of low current MAG welding was described by double-ellipse and uniform body heat source periodic loading. Moreover, the laser exerted an attraction and compression influence over the arc during the hybrid welding, which promoted the droplet transfer. Therefore, based on the novel MAG heat source, a hybrid Laser-MAG heat source in the short-circuit transition mode was developed. The laser beam heat source was described using a three-dimensional column heat source, the arc attraction and compression by the laser were considered indirectly through distribution parameter tuning for the double-ellipse model, and the laser-promoted transition effects of the droplets were described through the cycle frequency alterations of a double ellipsoid and homogeneous heat source. this heat source model was used to determine the MAG welding and hybrid welding temperature fields. Using hybrid Laser-MAG welding, a weld with a high depth-to-width ratio and complete penetration was obtained. The weld geometry and weld pool length were determined through welding tests, and the test results coincided with the fusion line trend and shape of the weld obtained by simulation, proving the rationality of the developed heat source model.

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Section: Introductionmentioning

confidence: 99%

An improved simulation of temperature field in Laser–low current

Xu,

Sun,

Han

et al. 2024

Preprint

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“…Li et al [39,40] established a prediction model for sidewall penetration in rotating arc narrow gap MAG welding with support vector machines, which can be used for penetration control. In addition, methods such as laser-arc hybrid welding [41][42][43], dual-wire or triplewire welding [44][45][46], and magnetic field-assisted welding [47,48] have also been used in narrow gap welding processes. A series of research studies focusing on arc characteristics, droplet transfer, process parameter optimization [49], oscillating arc, rotating arc, multiwire welding, hybrid welding, and magnetic field-assisted welding have significantly optimized weld formation and improved welding efficiency.…”

Section: Introductionmentioning

confidence: 99%

Effect of Increasing Oscillation Width on the Arc Characteristics and Droplet Transfer Behavior of X80 Steel in the Overhead Welding Position of Narrow Gap P-GMAW

Bao

Xue

Zhou

et al. 2023

Metals

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In the welding process of thick plate narrow gap pulse gas metal arc welding (P-GMAW) overhead welding station, the arc characteristics and droplet transfer behavior that become more complex due to the combined effects of narrow gap groove, gravity, and welding torch oscillation. The welding stability is more difficult to control. High-speed imaging and electrical signal acquisition systems were established to observe and record the arc behavior and droplet transfer during the welding process at different oscillation widths, further revealing the formation mechanism of welding seam in narrow gap P-GMAW overhead welding station. Research has found that with an increased oscillation width, the arc deflects towards the sidewall from a trumpet-shaped symmetrically distributed around the center of the groove at an increasing deflection angle, and the droplet transfer changes from one droplet per pulse to multiple droplets per pulse, resulting in defects such as lack of sidewall fusion and undercutting of the weld seam. Based on the welding process discussed in this study, it is recommended to use an oscillation width of 2.6 mm.

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