Laser Beam Welding

Metallurgical and Materials Eng.
Department
Faculty of Petroleum and Mining Engineering, Suez University
Welding Metallurgy, MTE 452 A1
Laser Beam Welding

Presented by:
• Eng Hend
4th Year Students, 2015/2016
1
Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Content:
1- Introduction.
2- Lasers used for LBW.
3-Types of LBW.
4- LBW Parameters.
5- Metals welded by LBW.
6- Welding Defects and Discontinuities
7- Industrial applications of LBW
8- Advantages.
9- Limitations. 2
1- Introduction:
Laser abbreviation:-
Light Amplification by Stimulated
Emission of Radiation
The main characeristics of laser beam:-

1. monochromatic (all photons have the same wave length)
2. coherent (all photons are in-phase)
3. parallel (low divergence of radiation)
3
4
drilling welding
1,8% 18,7%
others inscribe
9,3% 20,5%
cutting micro
44,3% electronics
5,4%
World Market by Applications

- All Types of Lasers -
5
Definition of laser beam welding:-
Laser welding is a fusion and non-contact

process that requires access to the weld zone
from one side of the parts being welded.
*Inert gas shielding is generally employed to prevent

oxidation of molten puddle and filler metal may
occasionally be used.
6
Why do we need laser for welding?

Traditional welding: Laser beam welding:
 Natural limitations to speed and  High energy density input process

productivity  Precisely controllable (close
 Thicker sections need multi- pass tolerence: ± 0.002 in.)
welds  Low heat input produces low
 A large heat input distortion
 Results in large and unpredictable  Does not require a vacuum (welds at
distortions atmospheric pressure)
 Very difficult to robotize  Filler metal may occasionally be used.
7
2-Lasers used for welding:

 Gas lasers: CO₂ Laser
He-Ne laser
 Solid state laser : Nd3+:YAG Lasers Lamp-pumped
LD-pumped
 Semiconductor laser: Diode Laser
 Other types: Disk Laser

Fiber Laser
8
Main characteristics of these types:-

Gas lasers:-
CO2 Laser: Characteristics He-Ne laser: Characteristics
Wavelength .633 µm; visible light
Wavelength 10.6 µm; far-infrared ray
Laser He-Ne mixture(10:1)
Laser CO2–N2–He mixed gas (gas)
Media
Media
Average 45 kW (maximum) Average 50 mW (fiber-coupling max.)

Power (Normal) 500 W – 10 kW Power [CW]
(CW)
Merits low divergence
Merits Easier high power (efficiency: 10–
20%)
9
Solid state lasers:-

Lamp-pumped YAG Laser: Characteristics LD-pumped YAG Laser: Characteristics
Wavelength 1.06 µm; near-infrared ray Wavelength about 1 µm; near-infrared ray
Laser Media Nd3+: Y3Al5O12 garnet (solid) Laser Media Nd3+ : Y3Al5O12 garnet (solid)
Average [CW] : 13.5 kW (fiber-coupling

Average 4 kW (cascade type & fiber- Power max.)
Power [CW] coupling)
[PW] : 6 kW (slab type max.)
(Normal) 50 W–4 kW
Merits Fiber-delivery, high brightness,

Fiber-delivery, and easier and high efficiency (10–20%)
Merits
handling (efficiency: 1–4%)
10
Semiconductor lasers:-
Diode Laser: Characteristics
Wavelength 0.8 to 0.95µm ; near-infrared ray
Laser Media semiconducting crystal, such as

gallium arsenide, lead selenide
Average up to 6 kW
Power [CW]
Merits • efficiency: approx. 30%

• almost maintenance-free
(diode life longer than 10.000
service hours)
11
Other types:-
Fiber Laser: Characteristics Disk Laser: Characteristics
Wavelength 1.07 µm; near-infrared ray Wavelength 1.03 µm; near-infrared ray
Laser Yb3+ : SiO2 (solid), etc. Laser Media Yb3+ : YAG or YVO4 (solid)
Media
Average 6 kW (cascade type max.)
Average 20 kW (fiber-coupling max.) Power [CW]
Power [CW]
Merits Fiber-delivery, high

Merits Fiber-delivery, high
brightness, high
brightness, high
efficiency(10–15%)
efficiency(10–25%)
12
13
3- Types of Laser Beam Welding:

3.1. Conduction Welding:
3.1.A. Description:
 Heating the work piece above
the melting temperature without
vaporizing.
 Heat is transferred into the material
by thermal conduction.
14
3.1.B. Characteristics:
1- Low welding depth( laser beam intensity: I < 10⁶ W/cm²)
2- Small aspect ratio (depth to width ratio is around unity)
3-Absorption at solid or liquid surface A < 30%
4- Very smooth, highly aesthetic weld bead
3.1.C. Applications:
Laser welding of thin work pieces like foils, wires, thin tubes,
enclosures, etc.
15
3.2. Keyhole (Deep Penetration) Welding:

3.2.A. Description:
 Heating of the work piece above
the vaporization temperature
and forming of a keyhole.
 Laser beam energy is transferred
deep into the material via a cavity
filled with metal vapour.
 Hole becomes stable due to
the pressure from vapour generated.
16
3.2.B. Characteristics:
1- High welding depth
(laser intensity: I > 10⁶ W/cm²)
2- High aspect ratio
(depth to width ratio can be 10:1)
3- Almost complete energy entry through absorption
by plasma: A > 90%.
Hint : Plasma Suppression
17
18
19
4- Laser Beam Welding Parameters:

 The main variables for LBW :
1- Incident laser beam power.

2- Incident laser beam diameter and the focal length.
3- Shielding gas.
4- Absorptivity.
5- Traverse speed of the laser beam across the
substrate surface.
20
4.1. Incident laser beam power:
 The depth of penetration with laser welding is directly

related to the power density of the laser beam and is a
function of incident beam power and beam diameter. For
a constant beam diameter, penetration typically increases
as the beam power is increased
21
4.2.Incident laser beam diameter and the

focal length:
22
 The dimensional relationship and effect of these two

factors is conveniently expressed as the f number.
which is derived by dividing the focal length, F, by the
incident beam diameter, D.
 f number , the beam waist diameter, d, and depth of

focus. L , the convergence angle θ
 Low f numbers produce smaller spot sizes and

therefore higher power densities which enable higher
welding speeds than with higher f numbers, they do
not ensure such good all round welding performance.
23
4.3. Shielding gas:
 The role of the shielding gas in laser welding:

1-To protect the weld keyhole and solidifying molten
metal from oxidation and thus avoid porosity and oxide
inclusions which give rise to poor weld quality.
2- To protect the transmission of the laser beam as it

comes to focus on the work and thus ensure good weld
penetration by minimising beam expansion and scattering,
which can be caused by vapours and gases around the weld
keyhole. 24
4.3.A. Shielding gases for Nd:YAG laser welding:
 Single spot welds can be made with Nd:YAG lasers

with no shielding gas at all.
 Continuous seam or butt welds, Argon or nitrogen

(nitrogen can cause embrittlement in certain steels) is
generally used with lasers rated up to about 300 W.
 Users of high power Nd:YAG lasers operating in the 1

kW average power range have reduced the problem
of penetration by using a 20% carbon dioxide, 80%
argon gas mixture or argon plus 1-2% oxygen
mixture. 25
4.3.A. Shielding gases for CO₂ laser welding:
 Helium is clearly the best of the common shielding

gases for performance and high quality CO₂ laser
welding because it has the highest ionisation potential,
which basically means it can absorb more energy
before breaking down and promoting an unacceptable
plasma formation.
26
4.3. Absorptivity:
 The efficiency of LBW depends on the absorption of light energy
by the workpiece.
 The infrared absorption of metal largely depends on the
Conductive absorption by free electrons;
 Absorptivity is a function of the electrical resistivity of the
substrate material (Ω. cm), and the emissivity of substrate
materials at certain temperature;
Electrical Resistivity (ρr) ↑ Absorptivity ↑
Emissivity (ελ) ↑ Absorptivity ↓
27
 Arata, Miyamoto and McCay et al. measured the absorptivity

of polished surfaces of various materials and concluded that
absorptivity is proportional to the square root of the resistivity:
 A temperature-dependent relationship between the electrical

resistivity and emissivity of the metal of a substrate for the
perpendicular incidence of radiation of certain wavelength (λ)
was derived by Bramson:
28
 Absorptivity can also be increased by the use of reactive gases;
 the addition of 10% O2 to an argon shielding gas gives an increase of up to 100%

in welding depth. The gas flow direction also had no significant effect on weld
profile;
Dependent of Various Materials
Wave Length Absorption
29
4.4.Traverse speed:
 Penetration depths achievable in LBW are dependent on the
beam power and welding speed.
 As the welding speed increases, the average power dissipated
in the sheet is expected to drop, why?!
- because as the welding speed increases, emissivity and

reflectivity increases, absorptivity decreases, the keyhole is no
longer a completely effective trap for the incident laser radiation;
Welding Speed ↑ Penetration Depth ↓
30
31
5- Metals welded by LBW:

 Method can be used to weld metals to themselves, as well as
dissimilar metals if they are metallurgically COMPATIBLE;
 Low carbon steels are weldable with LBW, but if Carbon Content
exceeded 0.25 martensitic transformation may take place and cause
brittle welds and cracking.
C% ↑ Ms ↓ higher degree of undercooling ↑
higher driving force for martensite formation ↑
32
33
 Steels containing sulfur exhibits high tendency to hot cracking due

to high heating rates in LBW
 Nitrided and Carburized steels show high tendency to cracking in

LBW due to high amount of porosity
 Stainless steels exhibits high weldability with laser beam welding

due to their lower thermal conductivity ↓
lower thermal conductivity ↓
Narrower welds == Welding Gap ↓
Deeper penetrations than for carbon steels ↑

34
 Titanium alloys and refractory materials are welded successfully

with LBW, But inert atmosphere must be applied to prevent
oxidation at high temperatures.
 Aluminium, Coppers and Brasses are successfully joind by LBW

with specialized weld design for conduction welding.
 Refractory metals such as tungsten are often conduction welded

but require higher power than other materials.
35
6-Welding Defects and Discontinuities:

 Porosity
• high cooling rate

• insufficient degassing
of the molten metal
• too low a weld speed
also may cause porosity
 Embrittlement
36
 Misalignment
 Mispositioning
37
 Edge preparation
 Gap
• Can be avoided by
using filler metal
38
39
7- Industrial applications of LBW:
40
8- Advantages :
• Low heat input produces low distortion.

• High aspect ratios .
• Thin metals can be welded.
• Small and closely spaced components can be welded.
• No electrodes are required.
• Beams can be focused and aligned.
41
• Wide variety of materials can be welded.

• Not influenced by magnetic fields.
• Metals with dissimilar physical properties can be welded.
• No vacuum or X-ray shielding required.
• Beams transmitted to many work stations.
42
9- limitations:
• Requires greater control of joint tolerance.

• Maximum weld penetration is limited to 19 mm.
• Expensive equipment.
• Consumes much energy.
• Requires Plasma control device.
• Alloy reflectivity and thermal conductivity.
43
Any
Question
44
Thanks For
Your
Attention
45

Laser Beam Welding

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Laser Beam Welding

Caricato da

Copyright:

Formati disponibili

Metallurgical and Materials Eng.

Welding Metallurgy, MTE 452 A1

Laser Beam Welding

The main characeristics of laser beam:-

World Market by Applications

Definition of laser beam welding:-

Laser welding is a fusion and non-contact

*Inert gas shielding is generally employed to prevent

Why do we need laser for welding?

 Natural limitations to speed and  High energy density input process

2-Lasers used for welding:

 Other types: Disk Laser

Main characteristics of these types:-

Average 45 kW (maximum) Average 50 mW (fiber-coupling max.)

Solid state lasers:-

Average [CW] : 13.5 kW (fiber-coupling

Merits Fiber-delivery, high brightness,

Wavelength 0.8 to 0.95µm ; near-infrared ray

Laser Media semiconducting crystal, such as

Merits • efficiency: approx. 30%

Merits Fiber-delivery, high

3- Types of Laser Beam Welding:

3.2. Keyhole (Deep Penetration) Welding:

4- Laser Beam Welding Parameters:

1- Incident laser beam power.

4.1. Incident laser beam power:

 The depth of penetration with laser welding is directly

4.2.Incident laser beam diameter and the

 The dimensional relationship and effect of these two

 f number , the beam waist diameter, d, and depth of

 Low f numbers produce smaller spot sizes and

4.3. Shielding gas:

 The role of the shielding gas in laser welding:

2- To protect the transmission of the laser beam as it

4.3.A. Shielding gases for Nd:YAG laser welding:

 Single spot welds can be made with Nd:YAG lasers

 Continuous seam or butt welds, Argon or nitrogen

 Users of high power Nd:YAG lasers operating in the 1

4.3.A. Shielding gases for CO₂ laser welding:

 Helium is clearly the best of the common shielding

 Arata, Miyamoto and McCay et al. measured the absorptivity

 A temperature-dependent relationship between the electrical

 Absorptivity can also be increased by the use of reactive gases;

 the addition of 10% O2 to an argon shielding gas gives an increase of up to 100%

- because as the welding speed increases, emissivity and

Welding Speed ↑ Penetration Depth ↓

5- Metals welded by LBW:

C% ↑ Ms ↓ higher degree of undercooling ↑

higher driving force for martensite formation ↑

 Steels containing sulfur exhibits high tendency to hot cracking due

 Nitrided and Carburized steels show high tendency to cracking in

 Stainless steels exhibits high weldability with laser beam welding

lower thermal conductivity ↓

Narrower welds == Welding Gap ↓

Deeper penetrations than for carbon steels ↑

 Titanium alloys and refractory materials are welded successfully

 Aluminium, Coppers and Brasses are successfully joind by LBW

 Refractory metals such as tungsten are often conduction welded

6-Welding Defects and Discontinuities:

• high cooling rate

7- Industrial applications of LBW:

• Low heat input produces low distortion.

• Wide variety of materials can be welded.