Model-based penetration depth estimation for laser welding processes

Abstract

Penetration depth is an important factor critical to the quality of a laser weld. This paper examines the feasibility of using temperature measurements on the bottom surface of the workpiece to estimate weld penetration. A three-dimensional analytical model relating penetration depth, weld bead width and welding speed to temperature distribution at the bottom surface of the workpiece is developed. Temperatures on the bottom surface of the workpiece are measured using infrared thermocouples located behind the laser beam. Experimental results from bead-on-plate welds on low carbon steel plates of varying thickness at different levels of laser power and speeds validate the model and show that the temperature on the bottom surface is a sensitive indicator of penetration depth. The proposed model is computationally efficient and is suitable for on-line process monitoring application.Penetration depth is an important factor critical to the quality of a laser weld. This paper examines the feasibility of using temperature measurements on the bottom surface of the workpiece to estimate weld penetration. A three-dimensional analytical model relating penetration depth, weld bead width and welding speed to temperature distribution at the bottom surface of the workpiece is developed. Temperatures on the bottom surface of the workpiece are measured using infrared thermocouples located behind the laser beam. Experimental results from bead-on-plate welds on low carbon steel plates of varying thickness at different levels of laser power and speeds validate the model and show that the temperature on the bottom surface is a sensitive indicator of penetration depth. The proposed model is computationally efficient and is suitable for on-line process monitoring application.