Abstract
An analysis presents a weld leakage problems of automotive pressure sensor, caused by weld crater cracking. A two-beam laser welding (TBLW) was used to weld a circumferential weld, which undesirably increases the probability of weld leakage by creating two weld end craters on a single weld. Microstructural analysis showed that microsegregation of alloying elements combined with imposed strains causes solidification cracking at the weld end crater. A novel “zigzag” laser power ramp-down was used and the results showed a limited crack propagation by producing significantly shorter discontinuous cracks. In such weld crater endings the leakage is no longer an issue.
Highlights
The use of laser microwelding for joining of high value components in technologically demanding high volume manufacturing has increased significantly in the recent years [1]
The subject of this study is the overlapping circumferential weld between a flange made of 17–4 precipitation hardened (PH) stainless steel (SS) and a plug made of nickel-based superalloy Inconel 602 CA
It can be noted that these crater cracks extend from the crater center towards crater edges in an X or branch shape
Summary
The use of laser microwelding for joining of high value components in technologically demanding high volume manufacturing has increased significantly in the recent years [1]. The attractiveness of laser welding for these precision applications lies in the possibility of welding pre-machined precision components with limited heat input and correspondingly minimized component distortions. Laser welding still generates distortions in the welded components causing dimensional inaccuracies [2]. These component distortions in precision welding, lead to further assembly problems or even affect the functionality of the product [3]. Strategies for reducing welding distortions are being investigated in laser welding. Bushenhenke et al [4] reported that in circumferential laser welding, distortions can be efficiently reduced by using two-beam laser welding (TBLW), in which two diametrically opposed laser beams simultaneously weld a circumferential weld [5]
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