Effect of laser welding parameters on fusion zone morphological,mechanical and microstructural characteristics of AISI 304 stainless steel

Nowadays, the Nd:YAG laser has been a promising key tool for joining thin components. In this research, mechanical and microstructural properties of laser welded thin austenitic stainless steel sheets were investigated with experimental investigations, as a function of laser welding parameters. Butt welded joints were made using a Nd:YAG laser in the pulsed wave mode. The appropriate laser welding parameters were found in order to obtain quality and strong weld seam. The pulsed laser seam welding process is controlled by a variety of parameters. We focus on the effects of the several processing parameters on mechanical and microstructural characteristics of joint and weld quality. The aim of this research was to evaluate the influence of these processing parameters on joint strength and microstructure. And also we examined the weldability of stainless steels in butt joint configuration by a pulsed Nd:YAG laser beam.     

Absorbing TiOx thin film enabling laser welding of polyurethane membranes and polyamide fibers

We report on the optical properties of thin titanium suboxide (TiO_x) films for applications in laser transmission welding of polymers. Non-absorbing fibers were coated with TiO_x coatings by reactive magnetron sputtering. Plasma process parameters influencing the chemical composition and morphology of the deposited thin films were investigated in order to optimize their absorption properties. Optical absorption spectroscopy showed that the oxygen content of the TiO_x coatings is the main parameter influencing the optical absorbance. Overtreatment (high power plasma input) of the fiber surface leads to high surface roughness and loss of mechanical stability of the fiber. The study shows that thin substoichiometric TiO_x films enable the welding of very thin polyurethane membranes and polyamide fibers with improved adhesion properties.     

A comparative study of laser beam welding and laser-MIG hybrid welding of Ti-Al-Zr-Fe titanium alloy

Ti-Al-Zr-Fe titanium alloy sheets with thickness of 4 mm were welded using laser beam welding (LBW) and laser-MIG hybrid welding (LAMIG) methods. To investigate the influence of the methods difference on the joint properties, optical microscope observation, microhardness measurement and mechanical tests were conducted. Experimental results show that the sheets can be welded at a high speed of 1.8 m/min and power of 8 kW, with no defects such as, surface oxidation, porosity, cracks and lack of penetration in the welding seam. In addition, all tensile test specimens fractured at the parent metal. Compared with the LBW, the LAMIG welding method can produce joints with higher ductility, due to the improvement of seam formation and lower microhardness by employing a low strength TA-10 welding wire. It can be concluded that LAMIG is much more feasible for welding the Ti-Al-Zr-Fe titanium alloy sheets.     

Absorbing TiOx thin film enabling laser welding of polyurethane membranes and polyamide fibers

Abstract

We report on the optical properties of thin titanium suboxide (TiO_x) films for applications in laser transmission welding of polymers. Non-absorbing fibers were coated with TiO_x coatings by reactive magnetron sputtering. Plasma process parameters influencing the chemical composition and morphology of the deposited thin films were investigated in order to optimize their absorption properties. Optical absorption spectroscopy showed that the oxygen content of the TiO_x coatings is the main parameter influencing the optical absorbance. Overtreatment (high power plasma input) of the fiber surface leads to high surface roughness and loss of mechanical stability of the fiber. The study shows that thin substoichiometric TiO_x films enable the welding of very thin polyurethane membranes and polyamide fibers with improved adhesion properties.     

Microstructure and mechanical properties of laser welded wrought ZK21 magnesium alloy

The as-rolled ZK21 magnesium alloy sheets of 2 mm in thickness were successfully joined by laser welding. The effects of the welding parameters including the laser power and the welding speed on the microstructure and mechanical properties of the joints were investigated. A sound bead, with the ultimate tensile strength (UTS) of 289 MPa and up to 94% of the base metal, was obtained with the optimized welding parameters. The fusion zone (FZ) was characteristic of equiaxed dendritic grains of about 15 μm in size and fine Mg₂Zn₃ precipitates dispersed among the dendritic arms. Besides, a few columnar grains grew from the fusion boundary epitaxially. The fine grains in the heat-affected zone (HAZ) were ascribed to recrystallization.     

基于BP神经网络薄板P-PAW搭接的间隙自适应工艺参数优化

对大型LNG燃料薄膜舱中1.2 mm厚SUS304L不锈钢板薄板的搭接焊,存在的搭接间隙会带来焊缝成形不良等严重影响船舱安全性的问题。本文通过激光传感器检测搭接间隙变化,设计了不同的峰值电流和焊接速度在不同间隙下的工艺实验,研究了间隙对焊缝成形质量的影响机制;基于BP神经网络建立不同间隙下的脉冲等离子弧焊(P-PAW)的工艺参数和间隙及焊缝成形尺寸之间的拓扑关系模型,通过工艺实验获取模型的训练样本,实现了基于BP神经网络的间隙自适应工艺参数优化系统。结果表明,该系统实现了不同搭接间隙下进行实时工艺参数优化的功能,并对搭接间隙在0～0.6 mm变化时所带来的空洞等缺陷起到了有效的抑制作用,实现了良好的焊接成形一致性控制,提高了在LNG薄膜舱中不锈钢板焊接的自适应能力。     

焊接参数对TC4薄板焊接过程的影响

目的 揭示焊接参数对TC4薄板焊接过程中温度场、位移场及应力场的影响规律。方法 基于有限元（FEM）模拟方法,运用Fortran语言对焊接热源及焊接参数进行定义,以模拟不同焊接参数下TC4薄板的TIG对接焊过程。结果 在稳弧阶段,温度场为一组以焊接方向为长轴的椭圆,且存在温度梯度,随着焊接速度的增大,温度场峰值、温度场温度梯度、熔池宽度和熔池体积逐渐减小,而焊接效率和焊接电流对温度场的影响与焊接速度刚好相反;随着焊接速度的增大,薄板最大变形量逐渐减小,焊接角变形及挠度变形逐渐得到改善,而焊接效率和焊接电流对位移场的影响与焊接速度刚好相反。在稳弧阶段,焊缝位置的残余应力为拉应力,两侧为压应力,随着焊接速度和焊接电流的增大,纵向残余拉应力逐渐增大,焊缝处高应力集中区的宽度逐渐减小,而焊接效率对应力场的影响与焊接速度刚好相反。在高焊接速度、中等焊接效率、低焊接电流参数条件下,可获得熔池体积小及熔池宽度窄的焊缝,有利于减小焊后残余应力与变形。结论 上述研究结果可为TC4薄板的焊接过程提供一定的理论指导。     

高速重复扫描激光塑料焊接工艺研究

目的 提高PA66塑料的焊缝剪切强度,达到实际生产要求.方法 采用高速扫描振镜对PA66塑料进行扫描激光焊接,分析重复焊接次数对塑料焊缝外观及剪切强度的影响,并且对焊缝截面进行测试,分析工艺参数对焊缝截面的影响规律.通过对工艺参数(激光平均功率、重复焊接次数、焊接速度、离焦量)进行四因素四水平正交实验,得到焊缝剪切强度...     

激光功率对钛合金双侧同步焊接温度场的影响

为研究激光功率对TC4钛合金T型结构双激光束双侧同步焊接温度场的影响,针对TC4钛合金T型结构的双激光束双侧同步焊接过程,建立了相应的有限元模型,利用有限元分析软件进行了焊接过程温度场的计算,研究了激光功率对熔池形状的影响规律,并对不同激光功率下的温度场进行了分析.结果表明:随着激光功率的增加,熔池的熔深、熔宽均有所增...     

Effects of process parameters on the quality aspects of weld-bead in laser welding of NiTinol sheets

The effects of process variables, like scan speed and laser power, on the quality of bead-on-plate welding of NiTinol sheets were investigated. The measured quality aspects for the weld-bead profile were bead geometry, changes in microstructure, variation of microhardness value along the weld-bead, extent of oxide contamination during welding, Ti/Ni ratio after welding, changes in tensile strength of the welded samples and corrosion behavior of the welded and parent materials. The laser weld-bead profile changed from the shape of a stemless wineglass to that with a prominent leg. Dimensional aspects of weld-bead geometry showed a decreasing trend with increasing scan speed. However, an increasing trend of the same was observed with power. The Ti/Ni ratio on the top surface after welding was found to decrease with scan speed at a particular power. Oxide contamination during welding followed the same pattern of variation as that of the Ti/Ni ratio. Microhardness values gradually increased from the weld centerline to the base metal. Formation of brittle intermetallic compounds reduced the tensile strength of the material after welding. A dual failure mode for the welded sample was observed, whereas a single mode of failure was detected for the parent material. The corrosion properties of the welded samples were better than that of the parent material.     

Small-scale resistance spot welding of austenitic stainless steels

Small-scale resistance spot welding (SSRSW) was carried out for austenitic stainless steels. A weld lobe that shows the process window for making sound joints was obtained for type 304 stainless steel thin sheets, and the effects of welding current, force and weld time on joint strength and nugget size were investigated. The cooling rate that was estimated from the solidification cell size was approximately 2.4 × 10⁵ K/s which is almost similar to that produced by laser beam welding. The microstructures of weld zones were almost fully austenitic due to the rapid solidification rate. Despite the fully austenitic microstructure, no hot cracking was found in types 302, 304, 316L, 310S and 347 austenitic stainless steels by SSRSW. Rapid cooling rate in SSRSW made it difficult to predict the microstructures from the conventional Schaeffler diagram.     

Analysis of process parameters effects on friction stir welding of dissimilar aluminum alloy to advanced high strength steel

Thin sheets of aluminum alloy 6061-T6 and one type of Advanced high strength steel, transformation induced plasticity (TRIP) steel have been successfully butt joined using friction stir welding (FSW) technique. The maximum ultimate tensile strength can reach 85% of the base aluminum alloy. Intermetallic compound (IMC) layer of FeAl or Fe₃Al with thickness of less than 1 μm was formed at the Al–Fe interface in the advancing side, which can actually contribute to the joint strength. Tensile tests and scanning electron microscopy (SEM) results indicate that the weld nugget can be considered as aluminum matrix composite, which is enhanced by dispersed sheared-off steel fragments encompassed by a thin intermetallic layer or simply intermetallic particles. Effects of process parameters on the joint microstructure evolution were analyzed based on mechanical welding force and temperature that have been measured during the welding process.     

A transient finite element simulation of the temperature and bead profiles of T-joint laser welds

Laser welding is a high power density welding technology, which has the capability of focusing the beam power to a very small spot diameter. Its characteristics such as high precision and low and concentrated heat input, helps in minimizing the micro-structural modifications, residual stresses and distortions on the welded specimens. In this study, finite element method (FEM) is adopted for predicting the bead geometry in laser welding of 1.6 mm thick AISI304 stainless steel sheets. A three-dimensional finite element model is used to analyze the temperature distribution in a T-joint weld produced by the laser welding process. Temperature-dependent thermal properties of AISI304 stainless steel, effect of latent heat of fusion, and the convective and radiative boundary conditions are included in the model. The heat input to the model is assumed to be a 3D conical Gaussian heat source. The finite element code SYSWELD, along with a few FORTRAN subroutines, is employed to obtain the numerical results. The T-joint welds are made using a Nd:YAG laser having a maximum power of 2 kW in the continuous wave mode. The effect of laser beam power, welding speed and beam incident angle on the weld bead geometry (i.e. depth of penetration and bead width) are investigated. Finally, the shapes of the molten pool predicted by the numerical analysis are compared with the results obtained through the experimentation. The comparison shows that they are in good agreement.     

Study of metallurgic and mechanical properties of laser welded heterogeneous joints between DP600 galvanised steel and aluminium 6082

This investigation focuses on the feasibility of heterogeneous welded joints between DP600 steel and aluminium 6082. The process adopted used a power laser in two modes: keyhole welding and laser-induced reactive wetting. All the results of the study show that the use of laser welding of galvanised sheets, in the keyhole mode, can achieve a joint shear strength of 140 MPa by optimising the process parameters and controlling the penetration, which must be limited to 600 μm. Another key factor with this welding method is control of the inter-sheet gap, which was achieved by using a clamping system that ensured a rigid joint while maintaining a constant gap sufficient to allow the escape of zinc vapour. This approach enabled an increase in shear strengths of 200 MPa to be obtained and the zinc acted as a beneficial factor to the welding process. With the laser-induced reactive wetting mode, the joint between galvanised sheets was more brittle because of the formation of a non-uniform reaction layer. With this mode, the presence of zinc is a factor that limits the growth of the reaction layer and, at the same time, leads to a mechanical deterioration of the joint; test results indicate that mechanical strength was limited to about 80 MPa.     

6063铝合金单模光纤激光焊接工艺研究

目的 针对采用脉冲激光点焊的6063铝合金焊点拉力较低,无法满足实际需求的问题,研究6063铝合金激光焊接的最优工艺方案,以提升焊点拉力.方法 采用单模光纤激光对6063铝合金进行焊接,通过极细的线宽组成螺旋点,代替单个脉冲激光点焊.对激光功率、焊接速度及离焦量等工艺参数进行正交实验,得到最佳工艺参数,并通过分析焊缝外...     

基于激光毛化的铝合金/CFRTP激光连接特性研究

目的 针对目前铝合金和碳纤维增强热塑性复合材料(CFRTP)直接连接接头强度低的问题,对铝合金表面进行预处理,以提升异种材料的激光连接强度。方法 通过激光毛化工艺在铝合金表面预制微织构,然后利用光纤激光连接铝合金与CFRTP,研究了激光焊接工艺参数对铝合金与CFRTP焊接接头拉剪性能的影响。结果 当激光功率为750 W、焊接速度为0.2 m/min时,铝合金/CFRTP接头拉剪力达到最大值5 209 N,是未激光毛化的接头拉剪力的2.29倍。通过扫描电镜(SEM)对断口进行分析,发现界面断裂形式主要为CFRTP脱出和剪切断裂。采用SEM及能谱仪(EDS)对接头截面进行分析,发现结合界面处存在微观机械嵌合作用,同时在界面处存在元素过渡层。结论 随着激光功率的增大,焊接接头的拉剪力增大,但焊接功率较大会导致热输入过大,造成树脂发生热分解,导致焊接接头拉剪力降低。随着焊接速度的增大,焊接热输入降低,导致焊接过程中树脂熔化量减少,焊接接头的拉剪力降低。界面的机械嵌合作用使焊接接头具有较高的结合强度。     

Influence of Cu2O surface treatment on the photovoltaic properties of Al-doped ZnO/Cu2O solar cells

Low cost Al-doped ZnO (AZO)/Cu₂O Schottky barrier solar cells with a high conversion efficiency of 2.19% were fabricated by depositing a transparent conducting AZO thin film on high quality Cu₂O sheets prepared by thermally oxidizing copper sheets. To achieve efficiencies higher than 2%, it is necessary to form the AZO thin film at a low deposition temperature using a low-damage deposition method, i.e., at room temperature by a pulsed laser deposition. In addition, the obtained efficiency could be enhanced with a surface treatment of the Cu₂O sheets, such as by applying a Pd-Sn catalyst layer as a coating or a rapid thermal annealing treatment at approximately 500 °C in air.     

8 mm厚T2紫铜功率调制激光-MIG复合焊

目的研究工艺参数与调制参数之间的相互作用对T2紫铜功率调制光纤激光-MIG复合焊过程热效率和稳定性的影响。方法分别设计并进行了平均功率、送丝速度与调制振幅和调制频率的三元二次回归正交试验。其中采用母材熔化区面积表征焊接过程的热效率,采用焊缝中的气孔数量表征焊接过程的稳定性。结果调制振幅约为平均功率的1/3时,母材熔化区面积最大,焊接过程热效率最高,振幅增大或减小都会使熔化区面积减小。平均功率主要决定了焊接过程的线能量,平均功率增大有助于增大母材熔化区面积。送丝速度的大小不仅影响焊接过程的能量输入,而且对熔池的流动行为影响较大。送丝速度过大易使熔池以及小孔失稳,降低焊接过程稳定性,因此送丝速度不宜过大。本研究条件下,10 m/min的送丝速度较为适宜。结论在优化的工艺参数和调制参数下进行功率调制激光-电弧复合焊,可以使8 mm厚紫铜焊接过程的热效率和稳定性同步提升。     

Life fatigue estimation of welding seams based on notch strains

When based on structural stress acting on shell elements, the stress simulation for welding seams on thin sheets provides no sufficient correlation with damages occurring during real component tests under operational load.The calculation technique on hand is based on the analysis of the operational strength behavior of crucial positions such as toe notches and root notches. The notches are fictitiously rounded with radii of 0.05 mm. The notch root stress reduced by the support effect (especially the microstructural support effect) has proved to be an appropriate stress criterion.In order to verify the universality of the method for other welding seam geometries as well, the fatigue strength behavior of H-specimen was not only simulated for MAG-welding seams but also for laser welding seams and spot welding.The fatigue life estimation was carried out in accordance with the critical plane method and by using the P_SWT–stress-cycle curve. The Miner rule was used as hypothesis of damage accumulation.     

船用钛合金高效焊接工艺研究

本试验以板厚为4mm的Ti70和16 mm的TA5两种钛合金为焊接对象,对等离子弧焊(PAW)、激光焊(LW)及激光-MIG复合焊3种高能量密度高效率的钛合金焊接方法进行了初步的工艺探索,得到了性能优良的焊接接头,研究成果丰富了实船建造的钛合金焊接工艺。