Abstract
The processing advantages of welding with high brightness and 1 μm wavelength laser sources have been well reported. However, it is also reported that such high brightness laser sources, whilst providing the necessary penetration depth and welding speed, may result in unacceptable levels of weld spatter. So far, the effects of process parameters on spatter formation have not been well studied on aluminium alloys. In this paper, systematic experimental trials were carried out on the AA5083 aluminium alloy plates to study the effects of different process parameters on the spatter generated. High speed imaging and numerical modelling (using the computational fluid dynamic, CFD) were used to understand the formation mechanisms of the spatter. Results show that the process parameters having the most influence on spatter formation are laser power, welding speed × focal length of the focusing unit, laser power squared × welding speed, laser power squared × focal length of the focusing unit. The welding process in aluminium alloy AA5083 aluminium alloy is quite unstable, the occurrence of spatter ejections is closely related to the turbulence in the melt pool, and full penetration welds tend to produce less spatter than partial penetration welds. To minimise spatter ejection, it is recommended that a high welding speed is used with the laser power just sufficient to achieve full penetration the joint geometry, and the focus position of the laser beam should be appropriately away from the top surface of the workpiece.
Article PDF
Avoid common mistakes on your manuscript.
References
Youhei A, Yousuke K, Hiroshi N, Koji N, Masami M, Seiji K (2014) Effect of reduced pressure atmosphere on weld geometry in partial penetration laser welding of stainless steel and aluminium alloy with high power and high brightness laser. Sci Technol Weld Join 19:324–332
Chen W, Pal M (2008) Dual-beam laser welding of ultra-thin AA 5052-H19 aluminum. Int J Adv Manuf Tech 39:889–897
Zhang C, Li G, Gao M, Yan J, Zeng XY (2013) Microstructure and process characterization of laser-cold metal transfer hybrid welding of AA6061 aluminum alloy. Int J Adv Manuf Tech 68:1253–1260
Yan J, Gao M, Li G, Zhang C, Zeng XY, Jiang M (2013) Microstructure and mechanical properties of laser-MIG hybrid welding of 1420 Al-Li alloy. Int J Adv Manuf Tech 66:1467–1473
Ren D, Liu L, Li Y (2012) Investigation on overlap joining of AZ61 magnesium alloy: laser welding, adhesive bonding, and laser weld bonding. Int J Adv Manuf Tech 61:1–10
Saha DC, Westerbaan D, Nayak SS, Biro E, Gerlich AP, Zhou Y (2014) Microstructure-properties correlation in fiber laser welding of dual-phase and HSLA steels. Mater Sci Eng A-Struct Mater Prop Microst Process 607:445–453
Blackburn JE, Allen CM, Hilton PA, Li L, Hoque MI, Khan AH (2010) Modulated Nd:YAG laser welding of Ti-6Al-4V. Sci Technol Weld Join 15:433–439
Li SC, Chen G, Zhang M, Zhou Y, Zhang Y (2014) Dynamic keyhole profile during high-power deep-penetration laser welding. J Mater Process Technol 214:565–570
Katayama S, Abe Y, Mizutani M, Kawahito Y (2011) Deep penetration welding with high-power laser under vacuum. Trans JWRI 40:15–19
You DY, Gao XD, Katayama S (2013) Visual-based spatter detection during high-power disk laser welding. Optics Lasers Eng 54(SI):1–7
Biffi CA, Previtali B (2013) Spatter reduction in nanosecond fibre laser drilling using an innovative nozzle. Int J Adv Manuf Tech 66:1231–1245
Kawahito Y, Mizutani M, Katayama S (2007) Investigation of high power fiber laser welding phenomena of stainless steel. Trans JWRI 36:11–15
Kaplan A, Westin E, Wiklund G, Norman P (2008) Imaging in cooperation with modeling of selected defect mechanisms during fiber laser welding of stainless steel. Proceeding of 27th International Congress on Applications on Lasers & Electro-Optics (ICALEO), California, USA. 789–798
Kaplan AFH, Powell J (2011) Spatter in laser welding. J Laser Appl 23(032005):1–7
Kim JK, Lim HS, Cho JH, Kim CH (2008) Bead-on-plate weldability of Al 5052 alloy using a disk laser. J Ach Mat Manuf Eng 28:187–190
Liu JW, Rao ZH, Liao SM, Wang PC (2014) Modeling of transport phenomena and solidification cracking in laser spot bead-on-plate welding of AA6063-T6 alloy. Part I-the mathematical model. Int J Adv Manuf Tech 73:1705–1716
Liu JW, Rao ZH, Liao SM, Wang PC (2014) Modeling of transport phenomena and solidification cracking in laser spot bead-on-plate welding of AA6063-T6 alloy. Part II-simulation results and experimental validation. Int J Adv Manuf Tech 74:285–296
Chang BH, Allen C, Blackburn J, Hilton P (2013) Thermal and fluid flow characteristics and their relationships with porosity in laser welding of AA5083. Phys Procedia 41:478–487
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Chang, B., Blackburn, J., Allen, C. et al. Studies on the spatter behaviour when welding AA5083 with a Yb-fibre laser. Int J Adv Manuf Technol 84, 1769–1776 (2016). https://doi.org/10.1007/s00170-015-7863-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-7863-y