Defining the keyhole modes – the effects on the weld geometry and the molten pool behaviour in high power laser welding of stainless steels

Keyhole welding, meaning that the laser beam forms a vapour cavity inside the steel, is one of the two types of laser welding processes and currently it is used in few industrial applications. Modern high power solid state lasers are becoming more used generally, but not all process fundamentals and phenomena of the process are well known and understanding of these helps to improve quality of final products. This study concentrates on the process fundamentals and the behaviour of the keyhole welding process by the means of real time high speed x-ray videography. One of the problem areas in laser welding has been mixing of the filler wire into the weld; the phenomena are explained and also one possible solution for this problem is presented in this study. The argument of this thesis is that the keyhole laser welding process has three keyhole modes that behave differently. These modes are trap, cylinder and kaleidoscope. Two of these have sub-modes, in which the keyhole behaves similarly but the molten pool changes behaviour and geometry of the resulting weld is different. X-ray videography was used to visualize the actual keyhole side view profile during the welding process. Several methods were applied to analyse and compile high speed x-ray video data to achieve a clearer image of the keyhole side view. Averaging was used to measure the keyhole side view outline, which was used to reconstruct a 3D-model of the actual keyhole. This 3D-model was taken as basis for calculation of the vapour volume inside of the keyhole for each laser parameter combination and joint geometry. Four different joint geometries were tested, partial penetration bead on plate and I-butt joint and full penetration bead on plate and I-butt joint. The comparison was performed with selected pairs and also compared all combinations together.

The effect of focal point parameters in fiber laser welding of structural steel

In this thesis the effect of focal point parameters in fiber laser welding of structural steel is studied. The goal is to establish relations between laser power, focal point diameter and focal point position with the resulting quality, weld-bead geometry and hardness of the welds. In the laboratory experiments, AB AH36 shipbuilding steel was welded in an I-butt joint configuration using IPG YLS-10000 continuous wave fiber laser. The quality of the welds produced were evaluated based on standard SFS-EN ISO 13919-1. The weld-bead geometry was defined from the weld cross-sections and Vickers hardness test was used to measure hardness's from the middle of the cross-sections. It was shown that all the studied focal point parameters have an effect on the quality, weld-bead geometry and hardness of the welds produced.

Thick Section Laser Beam Welding of Structural Steels: Methods for Improving Welding Efficiency

Laser beam welding (LBW) is applicable for a wide range of industrial sectors and has a history of fifty years. However, it is considered an unusual method with applications typically limited to welding of thin sheet metal. With a new generation of high power lasers there has been a renewed interest in thick section LBW (also known as keyhole laser welding). There was a growing body of publications during 2001-2011 that indicates an increasing interest in laser welding for many industrial applications, and in last ten years, an increasing number of studies have examined the ways to increase the efficiency of the process. Expanding the thickness range and efficiency of LBW makes the process a possibility for industrial applications dealing with thick metal welding: shipbuilding, offshore structures, pipelines, power plants and other industries. The advantages provided by LBW, such as high process speed, high productivity, and low heat input, may revolutionize these industries and significantly reduce the process costs. The research to date has focused on either increasing the efficiency via optimizing process parameters, or on the process fundamentals, rather than on process and workpiece modifications. The argument of this thesis is that the efficiency of the laser beam process can be increased in a straightforward way in the workshop conditions. Throughout this dissertation, the term “efficiency” is used to refer to welding process efficiency, specifically, an increase in efficiency refers an increase in weld’s penetration depth without increasing laser power level or decreasing welding speed. These methods are: modifications of the workpiece – edge surface roughness and air gap between the joining plates; modification of the ambient conditions – local reduction of the pressure in the welding zone; modification of the welding process – preheating of the welding zone. Approaches to improve the efficiency are analyzed and compared both separately and combined. These experimentally proven methods confirm previous findings and contribute additional evidence which expand the opportunities for laser beam welding applications. The focus of this research was primarily on the effects of edge surface roughness preparation and pre-set air gap between the plates on weld quality and penetration depth. To date, there has been no reliable evidence that such modifications of the workpiece give a positive effect on the welding efficiency. Other methods were tested in combination with the two methods mentioned above. The most promising - combining with reduced pressure method - resulted in at least 100% increase in efficiency. The results of this thesis support the idea that joining those methods in one modified process will provide the modern engineering with a sufficient tool for many novel applications with potential benefits to a range of industries.

Étude critique de la densité électronique et des températures (excitation et ionisation) d'un plasma d'aluminium induit par laser

La caractérisation de matériaux par spectroscopie optique d’émission d’un plasma induit par laser (LIPS) suscite un intérêt qui ne va que s’amplifiant, et dont les applications se multiplient. L’objectif de ce mémoire est de vérifier l’influence du choix des raies spectrales sur certaines mesures du plasma, soit la densité électronique et la température d’excitation des atomes neutres et ionisés une fois, ainsi que la température d’ionisation. Nos mesures sont intégrées spatialement et résolues temporellement, ce qui est typique des conditions opératoires du LIPS, et nous avons utilisé pour nos travaux des cibles binaires d’aluminium contenant des éléments à l’état de trace (Al-Fe et Al-Mg). Premièrement, nous avons mesuré la densité électronique à l’aide de l’élargissement Stark de raies de plusieurs espèces (Al II, Fe II, Mg II, Fe I, Mg I, Halpha). Nous avons observé que les densités absolues avaient un comportement temporel différent en fonction de l’espèce. Les raies ioniques donnent des densités électroniques systématiquement plus élevées (jusqu’à 50 % à 200 ns après l’allumage du plasma), et décroissent plus rapidement que les densités issues des raies neutres. Par ailleurs, les densités obtenues par les éléments traces Fe et Mg sont moindres que les densités obtenues par l’observation de la raie communément utilisée Al II à 281,618 nm. Nous avons parallèlement étudié la densité électronique déterminée à l’aide de la raie de l’hydrogène Halpha, et la densité électronique ainsi obtenue a un comportement temporel similaire à celle obtenue par la raie Al II à 281,618 nm. Les deux espèces partagent probablement la même distribution spatiale à l’intérieur du plasma. Finalement, nous avons mesuré la température d’excitation du fer (neutre et ionisé, à l’état de trace dans nos cibles), ainsi que la température d’ionisation, à l’aide de diagrammes de Boltzmann et de Saha-Boltzmann, respectivement. À l’instar de travaux antérieurs (Barthélémy et al., 2005), il nous est apparu que les différentes températures convergeaient vers une température unique (considérant nos incertitudes) après 2-3 microsecondes. Les différentes températures mesurées de 0 à 2 microsecondes ne se recoupent pas, ce qui pourrait s’expliquer soit par un écart à l’équilibre thermodynamique local, soit en considérant un plasma inhomogène où la distribution des éléments dans la plume n’est pas similaire d’un élément à l’autre, les espèces énergétiques se retrouvant au cœur du plasma, plus chaud, alors que les espèces de moindre énergie se retrouvant principalement en périphérie.

Optical emission spectroscopic studies on laser ablated zinc oxide plasma

Optical emission spectroscopic studies were carried out on the plasma produced by ablation of zinc oxide target using the third harmonic 355 nm of Q-switched Nd:YAG laser, in vacuum and at three different ambient gas oxygen pressures. The spatial variations of electron density Ne and electron temperature Te were studied up to a distance of 20 mm from the target surface. The kinematics of the emitted particles and the expansion of the plume edge are discussed. The optimum conditions favorable for the formation of high quality zinc oxide thin films are thereby suggested.

Optical Emission Diagnostics Of Laser Produced Plasma From Graphite And Yba2cu3o7

This thesis is entitled “OPTICAL EMISSION DIAGNOSTICS OF LASER PRODUCED PLASMA FROM GRAPHITE AND YBa2Cu3O7. The work presented in this thesis covers the experimental results on the plasma produced with moderately high power laser with irradiance range in between 10 GW cm 2 to 100 GW cm -2. The characterization of laser produced plasma from solid targets viz. graphite and high temperature superconducting material like YBa2Cu3O7 have been carried out. The fundamental frequency from a Q - switched Nd: YAG laser with 9 ns pulse duration is used for the present studies. Various optical emission emission diagnostic techniques were employed for the the characterization of the LPP which include emission spectroscopy, time resolved studies, line broadening method etc. In order to understand the physical nature of the LPP like recombination, collisional excitation and the laser interaction with plasma, the time resolved studies offer the most logical approach

Optical emission studies of C2 species in laser-produced plasma from carbon

Optical emission studies of C2 molecules in plasma obtained by Nd:YAG laser ablation of graphite in a helium atmosphere are reported for irradiances in the range (1–9:2/ x 1010 W cm−2. The characteristics of the spectral emission intensity from the C2 (Swan band) species have been investigated as functions of the distance from the target, ambient pressure and laser irradiance. Estimates of vibrational temperatures of C2 species under various irradiance conditions are made. Results of measurements performed under different ambient helium gas pressures are also discussed.

Optical emission studies of C2 species in laser-produced plasma from carbon

Optical emission studies of C2 molecules in plasma obtained by Nd:YAG laser ablation of graphite in a helium atmosphere are reported for irradiances in the range (1–9:2/ x 1010 W cm−2. The characteristics of the spectral emission intensity from the C2 (Swan band) species have been investigated as functions of the distance from the target, ambient pressure and laser irradiance. Estimates of vibrational temperatures of C2 species under various irradiance conditions are made. Results of measurements performed under different ambient helium gas pressures are also discussed.

Spectral Characterization of Laser Induced Plasma from Titanium Dioxide

Optical emission from TiO2 plasma, generated by a nanosecond laser is spectroscopically analysed. The main chemical species are identified and the spatio-temporal distribution of the plasma parameters such as electron temperature and density are characterized based on the study of spectral distribution of the line intensities and their broadening characteristics. The parameters of laser induced plasma vary quickly owing to its expansion at low background pressure and the possible deviations from local thermodynamic equilibrium conditions are tested to show its validity.

Spectral Characterization of Laser Induced Plasma from Titanium Dioxide

Optical emission from TiO2 plasma, generated by a nanosecond laser is spectroscopically analysed. The main chemical species are identified and the spatio-temporal distribution of the plasma parameters such as electron temperature and density are characterized based on the study of spectral distribution of the line intensities and their broadening characteristics. The parameters of laser induced plasma vary quickly owing to its expansion at low background pressure and the possible deviations from local thermodynamic equilibrium conditions are tested to show its validity.

Spectral Characterization of Laser Induced Plasma from Titanium Dioxide

Optical emission from TiO2 plasma, generated by a nanosecond laser is spectroscopically analysed. The main chemical species are identified and the spatio-temporal distribution of the plasma parameters such as electron temperature and density are characterized based on the study of spectral distribution of the line intensities and their broadening characteristics. The parameters of laser induced plasma vary quickly owing to its expansion at low background pressure and the possible deviations from local thermodynamic equilibrium conditions are tested to show its validity