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- Laser welding
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- The University of Manchester
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A statistical learning method for image-based monitoring of the plume signature in laser powder bed fusion
摘要： The industrial breakthrough of metal additive manufacturing processes mainly involves highly regulated sectors, e.g., aerospace and healthcare, where both part and process qualification are of paramount importance. Because of this, there is an increasing interest for in-situ monitoring tools able to detect process defects and unstable states since their onset stage during the process itself. In-situ measured quantities can be regarded as “signatures” of the process behaviour and proxies of the final part quality. This study relies on the idea that the by-products of laser powder bed fusion (LPBF) can be used as process signatures to design and implement statistical monitoring methods. In particular, this paper proposes a methodology to monitor the LPBF process via in-situ infrared (IR) video imaging of the plume formed by material evaporation and heating of the surrounding gas. The aspect of the plume naturally changes from one frame to another following the natural dynamics of the process: this yields a multimodal pattern of the plume descriptors that limits the effectiveness of traditional statistical monitoring techniques. To cope with this, a nonparametric control charting scheme is proposed, called K-chart, which allows adapting the alarm threshold to the dynamically varying patterns of the monitored data. A real case study in LPBF of zinc powder is presented to demonstrate the capability of detecting the onset of unstable conditions in the presence of a material that, despite being particularly interesting for biomedical applications, imposes quality challenges in LPBF because of its low melting and boiling points. A comparison analysis is presented to highlight the benefits provided by the proposed approach against competitor methods.
关键词： Process plume,Metal additive manufacturing,Laser powder bed fusion,Infrared imaging,In-situ monitoring,Zinc
更新于2025-11-28 14:24:20
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Analysis of microstructure and mechanical strength of lap joints of TZM alloy welded by a fiber laser
摘要： The application of molybdenum alloys to structural components is severely limited due to their poor weldability with serious defects of porosity and joint embrittlement after welding despite their high melting temperature, hot strength and creep resistance. A systematical experimental study has been conducted to explore the potential of laser welding of 0.5 mm-thick Titanium-zirconium-molybdenum (TZM) alloy in a lap welding configuration. Porosity was found to be the most serious problem in the TZM laser lap welding process. Introducing an interface gap of 0.09 mm had the most positive effect in reducing the porosity compared to using helium gas, different shielding gas flow rates, adding alloy element and different heat input rate. With the use of 0.09 mm-interface gap, the porosity of the weld joint was reduced to 3%. The tensile stress of the bead on plate (BOP) welded joint could achieve about 60% that of the base metal. The fracture stress of the lap welded joint obtained by using 0.09 mm-interface gap in tensile-shear test was about 142 MPa. The porosity and embrittlement were responsible for the reduction of the strength and ductility of the welded joint.
关键词： Porosity,Mechanical property,Molybdenum alloy,Laser welding
更新于2025-11-28 14:24:20
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Effect of pre-existing nuclei on crystallization during laser welding of Zr-based metallic glass
摘要： In this study, experiments are carried out in laser welding of a Zr-based (Zr52.5Ti5Al10Ni14Cu17.9) bulk metallic glass (BMG), pre-existing nuclei nucleus density has significant influence on its crystallization behavior. Based on the classical nucleation/growth theory, it is concluded that a small amount of pre-existing nuclei in a BMG can shift the time-temperature-transformation (TTT) curve from a well-known ‘C-shape’ to a ‘ε-shape.’ This result provides fundamental understanding on why the shape of the TTT curve for a heating process is different from that for a cooling process for the same BMG. Two quality factors were defined as a measure of the effect of pre-existing nucleus density. By integrating the classical nucleation/growth theory with the heat transfer model, the evolution of crystalline phase during laser welding for a BMG with pre-existing nuclei was studied, and the modeling predictions compared favorably with the experimental results.
关键词： Crystallization,Nucleation and growth,Laser processing,Metallic glasses,Amorphous alloys
更新于2025-11-28 14:24:20
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Influence of processing parameters on the microstructure and tensile property of 85 W-15Ni produced by laser direct deposition
摘要： The plate-like shape 85W-15Ni parts were produced by laser direct deposition technology with different processing parameters (laser power and scanning speed). The influence of processing parameters and their corresponding laser energy density on the microstructural characterization, phase composition and tensile property of 85W-15Ni samples was investigated. The results show that the relative density of samples increased with the laser energy density and the densification trend started to slow as the laser energy density reached 380-400 J/mm3, though the highest density value was obtained with laser energy of 425 J/mm3. With the increase of laser energy density, more disorder and fine W dendrites existed at the bonding region between deposition layers and more W-W grain boundaries formed at the central region of the layer. The 85W-15Ni samples produced with different processing parameters consisted of W and γ-Ni phase. To improve the tensile property, it is necessary to increase the laser energy density to obtain denser structure and reduce the residual pores or gaps. However, the excessive laser energy density resulted in the formation of more W-W grain boundaries that were detrimental to the tensile property. The best tensile properties were obtained at the laser energy density of 395 J/mm3.
关键词： 85W-15Ni,Laser direct deposition,Tensile property,Laser energy density,microstructural characterization
更新于2025-11-28 14:24:20
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Inline weld depth measurement for high brilliance laser beam sources using optical coherence tomography
摘要： As a result of the rapidly growing importance of applications in electro mobility that require a precisely defined laser weld depth, the demand for inline process monitoring and control is increasing. To overcome the challenges in process data acquisition, this paper proposes the application of a novel sensor concept for deep penetration laser beam welding with high brilliance laser sources. The experiments show that optical coherence tomography (OCT) can be used to measure the weld depth by comparing the distance to the material surface with the distance to the keyhole bottom measured by the sensor. Within the presented work, the measuring principle was used for the first time to observe a welding process with a highly focused laser beam source. First, a preliminary experimental study was carried out to evaluate the influence of the angle of incidence, the material, and the weld joint geometry on the quality of the sensor signal. When using a multimode fiber laser with a focus diameter of 320 μm, the measurements showed a distinct behavior for aluminum and copper. The findings about the measurement signal properties were then applied to laser beam welding with a single-mode fiber laser with a spot diameter of only 55 μm. The spot diameter of the OCT measuring beam was about 50 μm and thus only slightly smaller than that of the single-mode processing beam. A wide variety of tests were carried out to determine the limits of the measurement procedure. The results show that the application of OCT allows inline monitoring of the weld depth using both a multimode and a highly focused single-mode laser beam. In addition, various influences on the signal were identified, e.g., the material-specific melt pool dynamics as well as several characteristic reflection and absorption properties.
关键词： high brilliance laser beam sources,weld depth measurement,optical coherence tomography,laser beam welding
更新于2025-11-28 14:24:20
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Enhancement of weld strength of laser-welded joints of AA6061-T6 and TZM alloys via novel dual-laser warm laser shock peening
摘要： In this paper, an experimental study is presented on an investigation to improve the weld strength of laser-welded joints via post-processing by warm laser shock peening (wLSP). A dual-laser setup was utilized to simultaneously heat the sample to a prescribed temperature and to perform the wLSP process on the laser-welded joints of AA6061-T6 and TZM alloys. Joints in overlap and bead-on-plate configurations were created by laser welding by a high-power fiber laser and post-processed with wLSP. The tensile tests carried out on wLSP-processed AA6061-T6 samples demonstrate an enhancement in the strength by about 20% over as-welded samples and the ductility of samples processed by wLSP improved by 30% over as-welded samples. The bead-on-plate (BOP) welds of TZM alloy processed with wLSP demonstrated an enhancement in strength by about 30% and the lap welds processed with wLSP demonstrated an increase in the joint strength by 22%. Finite element analysis revealed that the depth and magnitude of compressive stresses imparted by wLSP were greater than room temperature laser shock peening (rtLSP), which contributed to the enhancement of the joint strength for processed samples.
关键词： Al6061,Warm laser shock peening,Strength improvement,Laser welding,TZM
更新于2025-11-28 14:24:20
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Influence of laser parameters on tensile shear strength of copper welds
摘要： The electrification of the power train in the automotive industry leads to the requirement of electrical connectors with high ampacities. These connectors are often realized using ultrasonic bonding technology. Substitution of ultrasonic welding by laser welding allows an increase of ribbon cross section by a factor of 5 and thus a similar increase of the maximum transferred current. The increased cross section leads to higher loads (at least by a factor of 5) applied to the weld seam during the process. To minimize the heat input, the weld seam strength in shear direction shall be maximized. The influence of different laser parameters on the ultimate tensile shear stress in lap joint configuration is investigated, based on representative specimen geometries (10 × 0.3 mm2). The variable parameters are: laser wavelength (IR around 1050 nm + frequency doubled 515 nm), focal diameters (42–300 μm), different temper conditions of the base material, process parameters (laser power 0.6–4 kW and feed rate 50–800 mm/s), and welding strategies (single pass welding, spatial beam modulation). The material used is Cu-ETP (>99.9% Cu). For all the investigated parameters, the observed failure mode is “fracture in the fusion zone.” The ultimate tensile shear stress for all experiments is around 188 N/mm2 even for parameter changes in the order of one magnitude. This is in contrast to the assumed relation between laser parameters and the mechanical properties. This contrast will be discussed.
关键词： load-carrying capacity,ductile welds,wobbling,fiber laser welding,shear strength
更新于2025-11-28 14:24:20
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HSS coating with keyholes in penetration produced by laser cladding process
摘要： This paper is devoted to the assurance of higher durability of hard coatings by using irregular method of laser cladding (LC). The purpose of this study was to demonstrate that by producing of keyhole mode LC coatings enables to create functionally graded structure in interface. This can contribute to decrease the gradient of trough-depth residual stresses of the coating-substrate system formed by dissimilar steels. Experimental work was carried out using precise LC system, which consists of industrial robot (KUKA) and 1kW Yb-fiber laser (IPG Laser). Experimental coatings were created on cold work tool steel substrate AISI D2 using high-speed steel (HSS) powder AISI M2. The properties of coatings produced by two different methods have been evaluated in the course of a comparative analysis by examination of morphology of transverse cross-sections, elemental composition, microhardness distribution inside coatings and tribological tests. Results showed that coating with keyhole mode in penetration had lower hardness due to a larger amount of dilution however the smooth transition of properties in the interface was obtained. Despite the significant difference in hardness both coatings demonstrated very similar tribological behaviour.
更新于2025-11-28 14:24:20
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Impact of fume particles in the keyhole vapour
摘要： During laser material processing, the energy of the laser beam needs to be efficiently and constantly transported to the processing zone to guarantee constant processing. However, spatters or ejected particles from the keyhole can absorb and scatter the laser energy leading to inhomogeneous heat input and can initiate defect occurrence like pore formation. The impact of ejected particles from the keyhole on the energy transport of the laser beam is not completely understood since they are difficult to observe due to the small size and high speeds of the ejections. In this work, the particle characteristics were derived from a simulation of the keyhole wall movement. The behavior of the calculated particles in a side shielding gas jet was calculated to derive the height, at which the particles leave the laser beam and are not interrupting the laser energy transfer to the processing zone. Low impulse values of the particles were calculated e.g., at defocusing positions slightly underneath the material surface, where also highest melt pool sizes were found. These observations indicate that the fume particles can be one reason to limit the energy delivery. An efficiency increase can be achieved by adjusting the keyhole parameters to a more stable keyhole.
更新于2025-09-23 15:23:52
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Direct observation of pore formation mechanisms during LPBF additive manufacturing process and high energy density laser welding
摘要： Laser powder bed fusion (LPBF) is a 3D printing technology that can print parts with complex geometries that are unachievable by conventional manufacturing technologies. However, pores formed during the printing process impair the mechanical performance of the printed parts, severely hindering their widespread application. Here, we report six pore formation mechanisms that were observed during the LPBF process. Our results reconfirm three pore formation mechanisms - keyhole induced pores, pore formation from feedstock powder and pore formation along the melting boundary during laser melting from vaporization of a volatile substance or an expansion of a tiny trapped gas. We also observe three new pore formation mechanisms: (1) pore trapped by surface fluctuation, (2) pore formation due to depression zone fluctuation when the depression zone is shallow and (3) pore formation from a crack. The results presented here provide direct evidence and insight into pore formation mechanisms during the LPBF process, which may guide the development of pore elimination/mitigation approaches. Since certain laser processing conditions studied here are similar to the situations in high energy density laser welding, the results presented here also have implications for laser welding.
关键词： Pore formation,Laser powder bed fusion,X-ray imaging,Laser welding,Additive manufacturing
更新于2025-09-23 15:21:01