Laser beam
welding
Laser :
Light Amplification By Stimulated Emission
Of Radiation
Electrons are atomic particles that exist at specific
energy levels. These energy levels are unique and are
different for every atom or molecule.
Electrons in outer rings are at higher energy levels than
those in the inner rings. A flash of light can bump
electrons to higher energy levels by the injection of
energy. When an electron drops from an outer ring to an
inner ring or level, the excess of energy is given off as
light.
The wavelength or the color emitted is related to the
amount of energy released.
Part of the laser light passes through
the semi-reflecting mirror and performs
the welding function.
produces a very high energy density
light beam, many times higher than is
possible with normal light
The energy -hot light- created at
the focal point in a relatively short time
(0.5 to 20 ms) heats the metal beyond
its melting point and thus enables a
weld.
Laser Power
Joules: The hot light energy
output is measured in joules.
This industry term by
definition is the capacity
for doing work. Hot light
energy output is determined
by the amount of voltage and
pulse-length selected by the
operator
Welding effects:
When a pulse of hot light
energy penetrates an
alloy, the resulting affect
creates gaseous, liquid,
and molten zones in the
bombardment area
Why do we need laser for welding?
Laser beam welding:
Traditional welding:
Natural limitations to speed and
productivity
Thicker sections need multi-pass
welds
A large heat input
Results in large and unpredictable
distortions
Very difficult to robotize
High energy density input process
single pass weld penetration up
to inch
High aspect ratio
High scanning speeds
Precisely controllable (close
tolerence: 0.002 in.)
Low heat input produces low
distortion
Does not require a vacuum (welds at
atmospheric pressure)
No X-rays generated and no beam
wander in magnetic field.
No filler metal required (autogenous
weld and no flux cleaning)
Relatively easy to automate
Materials need not be conductive
Typical commercial lasers for welding
1.
CO2 Laser
2.
Nd3+:YAG Lasers
3. Diode Laser
CO2 Laser: Characteristics
Wavelength
10.6 m; far-infrared ray
Laser Media CO2N2He mixed gas (gas)
Average
45 kW (maximum)
Power (CW) (Normal) 500 W 10 kW
Merits
Easier high power (efficiency: 10
20%)
YAG Laser
YAG Laser Application: Automobile Industries
Effect parameters while
welding metals is as follows:
The voltage first influences the welding
depth.
The pulse length predominantly influences
the diameter of the welding point.
The focus influences the welding depth as
well as the diameter of the welding spot.
When increasing the diameter, the welding
depth is reduced at the same time.
Primary Adjustable Parameters and
Their Effects
Primary Controllable Parameters
Laser Beam Energy Output Characteristics
(i) Voltage
(ii) Pulse Duration
Laser Focus Characteristic
(iii) Laser Beam Diameter
Change in Voltage
Increased voltage results in deeper
physical penetration with less melting
due to physical pressure
Change in Beam Diameter
Change in Pulse Duration
Increased pulse duration results in
deeper and wider melting
Change in Voltage and Pulse
Duration
Simultanous increase in voltage and
pulse duration results in deeper melting
Increased beam diameter results in
shallow soft penetration and wide, but
soft melting
Lasers Beam Welding:
Types of LBW
Conduction Welding
Description
Heating the workpiece above the melting
temperature
without vaporizing
Heat is transferred into the material by
thermal conduction.
Characteristics
Low welding depth
Small aspect ratio (depth to width ratio is around
unity)
Low coupling efficiency
Very smooth, highly aesthetic weld bead
Applications
Laser welding of thin work pieces like foils, wires,
thin tubes, enclosures, etc.
Lasers Beam Welding:
Types of LBW
Keyhole Welding
Description
Heating of the workpiece above the
vaporization temperature and forming of a
keyhole
Laser beam energy is transferred deep
into the material via a cavity filled with
metal vapor
Hole becomes stable due to the
pressure from vapor
generated
Characteristics
High welding depth
High aspect ratio (depth to width
ratio can be 10:1)
High coupling efficiency
Lasers Beam Welding:
Laser welding unit
Beam
Delivery
unit
Schematic
Diagram
Beam Delivery Unit
Laser
Processing
Optics
Workpiece Positioning Unit
Joining Metals
Joint Preparation: To ensure a
strong laser welding joint it is
important to properly evaluate your
application and material thickness
first before selecting one of the joint
preparation methods
Bonding the joint: Strong
homogenous allow flow is achieved using
the appropriate parameter combinations
and the 50% overlap firing method. This
ensures a structurally sound joint while
virtually eliminating the possibility of
gaseous pockets or cold welds
Surface filling the joint: laser
welding vaporizes some of the alloy.
Filler material is used to fill these
voids. The filler material should be the
same alloy if possible. Filler wire
diameter should be no lager than
0.50mm or .020.
Filler Materials
Large gaps: Require fabricating a
large insert (often thick wire or
casted piece) of the same material
Small gaps: often require a quick
application of a thin filler wire to
correct or complete the laser
welding application
Shallow blemishes: require a
quick application of a thin filler wire
to correct the laser welding
application
Porosity
Deep porosity: can be repaired
in two steps: first using high
voltage-short pulse duration with
a tight beam diameter, burnout
any investment remaining and
expose the complete porosity
pocket; Second, use the filler
material to refill the porosity
pocket
Hammering and
Smoothing
After the core laser welding
process has been completed, it
is recommended to adjust to a
lower power, wide laser pulse
diameter and medium to fast
auto-pulsing setting. This will
smooth over or hammer the
surface which eliminates most
rough surfaces and reduces
secondary finishing techniques
to the laser welded area.
Thank You for
Patience Hearing
