Spatter Formation in Laser Welding with Beam Oscillation

“…Possible oscillating movements are linear (one-dimensional movement transverse to the feed direction), circular, elliptical, and octagonal. The use of circular oscillation has gained acceptance in laser beam micro welding because experiments have shown that molten pool ejections are reduced compared to other forms of oscillation and conventional welding [22][23][24].…”

Section: Theoretical Principlesmentioning

confidence: 99%

High-Precision Adjustment of Welding Depth during Laser Micro Welding of Copper Using Superpositioned Spatial and Temporal Power Modulation

Hummel

Häusler

Gillner

2021

JMMP

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For joining metallic materials for battery applications such as copper and stainless steel, laser beam micro welding with beam sources in the near-infrared range has become established in recent years. In laser beam micro welding, spatial power modulation describes the superposition of the linear feed motion with an oscillating motion. This modulation method serves to widen the cross-section of the weld seam as well as to increase the process stability. Temporal power modulation refers to the controlled modulation of the laser power over time during the welding process. In this paper, the superposition of both temporal and spatial power modulation methods is presented, which enables a variable control of the weld penetration depth. Three weld geometries transverse to the feed direction are part of this investigation: the compensation of the weld penetration depth due to the asymmetric path movement during spatial power modulation only, a W-shaped weld profile, and a V-shaped. The weld geometries are investigated by the bed on plate weld tests with CuSn6. Furthermore, the use of combined power modulation for welding tests in butt joint configuration between CuSn6 and stainless steel 1.4301 with different material properties is investigated. The study shows the possibility of precise control of the welding depth by this methodology. Depending on the material combination, the desired regions with maximum and minimum welding depth can be achieved by the control of local and temporal power modulation on the material surface.

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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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Spatter Formation in Laser Welding with Beam Oscillation

Cited by 83 publications

References 17 publications

Welding techniques for battery cells and resulting electrical contact resistances

Welding techniques for battery cells and resulting electrical contact resistances

High-Precision Adjustment of Welding Depth during Laser Micro Welding of Copper Using Superpositioned Spatial and Temporal Power Modulation

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

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