Vapor Capillary Research Articles

Analysis of laser beam welding with superimposed 445 and 1070 nm wavelength lasers on copper by in situ synchrotron diagnostics

In laser welding, precision and reproducibility are fundamentally dependent on temporal and spatial processes of energy input. Induced by the dynamics of the melt pool, pressure equilibria in the vapor capillary, and solidification behavior, different weld seam qualities are achieved. To obtain the lowest possible defect frequency, new tailored joining strategies need to be investigated using multibeam and multiwavelength approaches. To improve the quality by influencing the process dynamics, a dual-beam approach is investigated that superimposes a stationary laser beam with a wavelength of 445 nm with a spatially modulated laser beam with a wavelength of 1070 nm. The aim is to utilize ∼10 times higher absorption of a 445 nm diode laser on copper with the high focusability of a 1070 nm fiber laser. In this context, the influence of the relative positions of the two beams to each other on the weld seam quality is investigated, while one of the beams moves either in front, behind, or coaxial to the other beam following the path of a line weld. The main objective is to observe how the laser beams influence each other and how the capillary depth and porosity vary for different parameters. To visualize the process dynamics, the welding experiments on copper are performed at the Deutsches Elektronen-Synchrotron DESY by means of in situ phase contrast videography. Quality-determining weld properties like the distribution of pores or process fluctuations are then extracted automatically from the image sequences by means of a trained neuronal network.

Development workflow based on in situ synchrotron investigations to optimize laser processing of copper pins

To design future laser manufacturing processes for welding of copper materials, more and more high-end analysis methods are required. A fundamental process understanding by analyzing cause-and-effect relations of process dynamics using inline in situ diagnostics allows for an improved description of laser material interaction. Strategies for a reliable and robust welding process are derived from the findings. In this study, a four-step advanced methodical approach is presented and discussed. In the first step, a fundamental process description of the geometry of the vapor capillary and the formation of weld defects is developed. Therefore, welds on electrolytic tough pitch copper (Cu-ETP) and CuSn6 are carried out to analyze the temporal and spatial vapor capillary dynamics depending on laser power, welding speed, and focal diameter. This fundamental process understanding is transferred to the welding of copper pins in the form of I-pins. For this purpose, impurities and imperfections were applied to the pin surface to investigate the effects on the process result. As a third step, strategies by means of laser intensity distributions were adapted to compensate for imperfections in the welding process. Finally, a sensor vision system is adapted for ideal welding results. Investigations are based on in situ synchrotron analysis at Petra III, DESY in Hamburg. For the experiments, a TRUMPF TruDisk laser (100/400 μm fiber diameter), a TRUMPF TruFiber 6000P (50/100 μm fiber diameter), and a single-mode fiber laser (14 μm fiber diameter) were used. The focal diameter was adjusted with the optical system depending on the investigation.

Analyzing multispectral emission and synchrotron data to evaluate the quality of laser welds on copper

The validation of laser welding of metallic materials is challenging due to its highly dynamic processes and limited accessibility to the weld. The measurement of process emissions and the processing laser beam are one way to record highly dynamic process phenomena. However, these recordings always take place via the surface of the weld. Phenomena on the inside are only implicitly recognizable in the data and require further processing. To increase the validity of the diagnostic process, the multispectral emission data are synchronized with synchrotron data consisting of in situ high-speed images based on phase contrast videography. The welding process is transilluminated by synchrotron radiation and recorded during execution, providing clear contrasts between solid, liquid, and gaseous material phases. Thus, dynamics of the vapor capillary and the formation of defects such as pores can be recorded with high spatial and temporal resolution of <5 μm and >5 kHz. In this paper, laser welding of copper Cu-ETP and CuSn6 is investigated at the Deutsches Elektronen-Synchrotron (DESY). The synchronization is achieved by leveraging a three-stage deep learning approach. A preprocessing Mask-R-CNN, dimensionality reduction PCA/Autoencoders, and a final LSTM/Transformer stage provide end-to-end defect detection capabilities. Integrated gradients allow for the extraction of correlations between defects and emission data. The novel approach of correlating image and sensor data increases the informative value of the sensor data. It aims to characterize welds based on the sensor data not only according to IO/NIO but also to provide a quantitative description of the defects in the weld.

Selected properties of X120Mn12 steel welded joints by means of the plasma-MAG hybrid method

The article describes properties of welds made of high wear resistance X120Mn12 steel obtained by the hybrid PTA-MAG (plasma transferred arc – metal active gas) method. The specimens were 8 mm thick rectangular (200 mm × 350 mm) sheets metal. The analyzed butt welds were made with the parameters selected according to the criterion of smallest cross-sectional area of welds and the narrowest HAZ (heat affected zone). The outcome of metallographic tests of weld, HAZ and parent material, hardness distribution and XRD (X-ray diffraction) patterns of selected areas are presented. The IIT (Instrumented Indentation Test) method was used to describe the distribution of mechanical properties shaped by thermal cycle annealing of the welding process. The investigation shows that the application of the PTA-MAG hybrid heat source for welding manganese steel enables the use of the filler material ER307 (AWS-A5.9). The hybrid PTA-MAG welding system has the relatively high potential to be an efficient alternative to welding standard processes for X120Mn12 steel due to the HAZ overheating limitation. The zone of high-risk weld cracking is the part of the HAZ close to the fusion area that has been reheated during weldment formation. Heat input about 0.6 kJ/mm is needed to provide full deep penetration butt weld without defects and with a vapor capillary of wide enough to cover the weld gap. The increase of hardness in the welded joint is smooth distributed and going up to 10% compared to the base material. The width of HAZ was <1 mm. Intensive carbides precipitation in HAZ has been avoided successfully.

Controlling the weld penetration depth of laser beam micro welding by using an iterative learning approach

AbstractIn order to meet the increasing demand for high‐speed joining processes, laser beam micro welding is used to reproducibly weld metallic joining partners such as steel. Long weld seams or high cycle speeds, however, remain a challenge to achieve a constant welding depth throughout the entire welding process without major fluctuations. This paper shows the development and evaluation of a weld penetration depth control system based on interferometric measurement of the depth of the vapor capillary. High path speeds and small weld depths are challenging for real‐time depth control. Therefore, the offline data of the interferometric measurements are used to implement an iterative learning control of the weld penetration depth. The quality of the control is verified by welding with and without spatial power modulation on 1.4301 steel while following a linear and sinusoidal trajectory.

In Situ Synchrotron Investigations of Beam Diameter Influence on Vapor Capillary Formation during Laser Beam Welding of Copper Alloy with a Blue Laser Beam Source

Laser beam welding as a reliable tool for high-precision joining of batteries or microelectronics is more and more the choice for achieving reproducible results in production processes. In addition to a high automation capability, the precise control of the energy deposition into the material plays an important role, especially when highly reflective materials, such as copper or aluminum, must be welded together. Alongside the use of highly brilliant fiber lasers in the near-infrared range with a focal diameter of a few tens of micrometers, diode lasers in the wavelength range of 445 nm are increasingly being used. Here, beam diameters of a few hundred micrometers can be achieved. With a wavelength of 445 nm, the absorptivity in copper can be increased by more than a factor of 10 compared to a near-infrared laser beam sources in solid state at room temperature. This paper presents the in situ X-ray observation of laser welding processes on CuSn6 with a laser beam source with a wavelength of 445 nm using synchrotron radiation at DESY Petra III Beamline P07 EH4 in Hamburg, Germany. For the experiments, the laser radiation was focused via two separate optics to focal diameters of 362 µm and 609 µm. To characterize the dynamics of the vapor capillaries depending on the different focal diameters dF, the parameters were varied with respect to laser power PL and feed rate v. For the investigations, a synchrotron beam of 2 × 2 mm2 in size with a photon energy of 89 keV was used, and the material samples were analyzed by means of phase-contrast videography to show the boundaries between solid, liquid, and gaseous material phases. The results of this paper show the welding depths achieved and how the geometry of the vapor capillary behaves by changing the focal diameter, laser power and feed rate.

Numerical modeling of the temperature distribution and melt flow in dissimilar fiber laser welding of duplex stainless steel 2205 and low alloy steel

The research outlined in this paper pertains to the computational modeling and experimental investigation of laser keyhole welding between duplex stainless steel 2205 and low carbon steel (A516). A crucial aspect of keyhole welding entails predicting the phase transition behavior of the materials involved. The vaporized metal generates a recoil pressure and distorts the interface between the liquid and vapor phases, thus forming a vapor capillary. A multiphysics model employing the finite volume method was proposed to achieve a highly accurate simulation of the temperature and velocity fields. The findings demonstrate that the resulting weld bead relies heavily on the keyhole's structural characteristics. Additionally, analysis of the temperature distribution at a specific temporal and spatial point reveals that duplex stainless steel exhibits elevated temperatures owing to low thermal penetration at a distance of 5 mm from the juncture of the two components compared to A516. The numerical simulation results were in good agreement with experimental results for prediction of temperature filed and melt flow that have impact on weld bead and melt pool geometry. The weld bead width changes according to variation of welding speed and laser power has been in good agreement with the temperature distribution at upper surface of the workpiece extracted from simulation results. The melt pool geometry predicted from the simulation results (melt flow and temperature field) has been in good agreement with the melt pool geometry of the experiment. The temperature distribution from simulation results has a good correlation with the microstructural changes of the melt pool region according to the melting, solidification and temperature gradient at the melt pool region and adjacent HAZ of base metals.

Response of the melt pool and vapour capillary on dynamic beam shaping in the kHz regime during laser welding

Beam shaping technologies provide the possibility to distribute the optical energy of the laser beam on the workpiece in multiple ways. One of the latest technologies is coherent beam combining (CBC) of 32 fiber lasers, which allows quasi-instantaneous switching of beam shapes during laser material processing with frequencies up to 10 MHz. A study was performed for laser welding of stainless steel 1.4301, to investigate the influence of the switching frequency between two beam shapes on the capillary shape. Therefore, the beam shape was switched between a single spot and four spots, which leads to a maximum intensity variation. Frequencies between 10 Hz and 10 kHz were investigated. The results show, that the melt pool shape and the capillary shape follow the switching frequency until a limit frequency.

Comparative Analysis of Weld Microstructure in Ti-6Al-4V Samples Produced by Rolling and Wire-Feed Electron Beam Additive Manufacturing

The microstructure and phase composition of electron beam welded Ti-6Al-4V titanium alloy were studied by optical and scanning electron microscopy, backscattered electron diffraction, and X-ray diffraction analysis. Deep-penetration electron beam welds were made in a single pass on rectangular Ti-6Al-4V samples obtained by rolling and wire-feed electron beam additive manufacturing. It was found that the weld width in the 3D printed Ti-6Al-4V samples is greater than in the rolled material. The influence of the vapor capillary on the size, shape and structure of primary β grains formed in the fusion zone was shown. The variation of the penetration coefficient, volume fraction of the residual β phase, and residual stresses along the weld length was studied for Ti-6Al-4V samples obtained by both rolling and 3D printing.

In situ X-ray phase contrast imaging of the melt and vapor capillary behavior during the welding regime transition on aluminum with limited material thickness

The X-ray phase contrast imaging is a powerful method to understand the fundamental behavior of the melt and keyhole during the laser beam welding process. In this paper, the keyhole-induced vapor capillary formation in the melt pool is investigated by using an adjustable laser beam source. For this purpose, the aluminum A1050 specimen with a thickness of 0.5 mm is molten only with the heat conduction welding regime by using the ring-mode laser beam. Once the specimen is molten through, the core multi-mode laser beam is then applied to vaporize the melt and a transition to keyhole welding regime occurs. Therefore, the core multi-mode laser beam with an intensity value of 33.3 MW/cm2 is investigated. The correlation between the keyhole-induced vapor capillary and the melt behavior is further investigated in this paper which was recorded with a high sampling rate of 19 kHz. In addition, a theoretical calculation about the keyhole depth is discussed in this paper.

Towards an Understanding of the Challenges in Laser Beam Welding of Copper – Observation of the Laser-Matter Interaction Zone in Laser Beam Welding of Copper and Steel Using in Situ Synchrotron X-Ray Imaging

The increasing demand for contacting applications in electric components such as batteries, power electronics and electric drives is boosting the use of laser-based copper processing. Laser beam welding is a key for an efficient and high-quality electric vehicle production due to its local, non-contact energy input and high automation capability enabling reproducible weld quality. Nevertheless, a major challenge in process design is the combination of energy-efficiency and precise process guidance with regard to weld seam depth and defect prevention (i.e. spatter, melt ejections), partly caused by the high thermal conductivity of copper. High power lasers in the near infrared range and emerging visible laser beam sources with excellent beam quality can provide a suitable joining solution for this purpose. However, the underlying physical phenomena are currently only partly understood and a reflection on the challenges of laser beam welding of copper compared to well researched steel processing has not yet been carried out. In order to improve the understanding of the effect of the different material properties and the influence of process parameters on the vapor capillary and melt pool geometry in laser beam welding, in situ synchrotron investigations on Cu-ETP and S235 using 515 and 1030 nm laser sources were conducted. The material phase contrast analysis was successfully used to distinguish vapor capillary and melt pool phase boundaries during the welding process with high spatial and temporal resolution up to 5 kHz. A significantly different vapor capillary geometry and sensitivity to parameter variation were found between the steel and copper material. In addition, the visualization of characteristic melt flows revealed different melt pool dynamics and a pronounced eddy close to the melt pool surface for copper, which is assumed to be causal for the observation of pronounced spatter formation during copper welding in a certain process window.

Keyhole-in-keyhole formation by adding a coaxially superimposed single-mode laser beam in disk laser deep penetration welding

Laser deep penetration welding is characterized by the formation of a vapor capillary (keyhole) and a high overall absorption (coupling rate) of the laser radiation in comparison to heat conduction welding. Due to multiple reflexions within the highly dynamic keyhole, the absorption mechanisms are very complex. The questions, how a laser beam interacts with the existing keyhole, and, if shadowing effects occur, are a matter of concern for several researchers. In this study, the hypothesis that the beam of a laser source can be transmitted to a significant extent through an existing keyhole and acts predominantly at the keyhole bottom was investigated. Experiments were carried out on mild steel and technical pure aluminum, using a specially designed optical system, which allows to coaxially combine two laser beams and to adjust their settings like the energy and the focal plane individually. A combination of a disk laser with a focal diameter of 390 µm and a single-mode fiber laser with a focal diameter of 30 µm was used. Weld depths and seam shapes were analyzed in cross and longitudinal sections. Based on the results, it is shown that the much smaller focal diameter of the single-mode laser beam acted at the bottom of the keyhole and caused a kind of “keyhole-in-keyhole formation” in the form of a local maximum in weld depth whose expression depended on the focal plane of the single-mode laser beam.

In-situ x-ray phase contrast observation of the full penetration spot welding on limited aluminum material thickness

The laser-spot welding process of aluminum alloy 1050A with a limited thickness is observed with the x-ray phase contrast method to investigate the melt dynamic especially when the melt penetrates the material. The laser-spot welding is investigated with two different wavelengths of the laser beam source: 515 and 1030 nm to investigate the influence of the absorptivity. The melt progressively penetrates the material during the spot-welding process until reaching the bottom side of the material and when the melt penetrates the lower side of the material, the so-called “lens-like” melt appears at the lower side due to the surface tension. At a comparable beam intensity value, the oscillation of the “lens-like” melt at the lower side of the material is driven by the expansion of vapor capillary. This expansion occurs inside of the material and directly above the “lens-like” melt. The shape of the expanded vapor determines the volume as well as the geometry of the resulting melt volume. Furthermore, the transition from the heat conduction welding mode to the keyhole welding mode is investigated by defocusing the laser beam for the beam source with a 515 nm wavelength. At a given variation, a clear difference between either mode is observed with the x-ray phase contrast method.

Schlieren methodology for laser beam welding under vacuum

High-quality welds with high penetration depths can be achieved with laser beam welding under vacuum. The background to this process result continues to be the subject of a wide variety of research activities. In order to gain a better understanding of the outflow behavior of the resulting process emissions, the Schlieren technique was applied to an experimental setup for laser beam welding under vacuum. Using the Schlieren technique, the resulting flows above the welding process could be visualized for different pressure ranges from 100 hPa to 1,000 hPa. The Schlieren images clearly show the different formations of the welding plume for laser beam welding under vacuum. With digital image processing, the Farnebäck algorithm was used to estimate the flow velocities in the Schlieren images quantitatively. The results for the maximum flow velocities are in the range greater than 100 m/s for laser welds at atmospheric pressure and decrease with decreasing working pressure. Apart from the lower boiling temperatures in a vacuum, a reduced pressure difference within the vapor capillary is assumed to be a reason. In addition, the influence of different process parameters on the resulting flow velocities for laser welding under vacuum was quantified.

Analysis of the laser welding keyhole using inline coherent imaging

Laser beam welding is a widely used fusion welding process in many industrial applications such as automotive, aerospace, energy, defense, and medical products. Industry has a fundamental need to model the laser welding process to minimize experimental testing and improve confidence in production welds. However, computational models attempting to predict weld formation are limited by an incomplete understanding of the beam-material interactions. As a consequence, these models do not accurately predict the mechanisms associated with laser weld formation. To improve the current state of prediction capabilities, it is vital to better detect/measure the physical aspects of the weld pool during high energy density welding. In this work, a novel real-time laser weld monitoring device using inline coherent imaging (ICI) was used to provide a fundamental understanding of laser weld formation via vaporization.The objective of this work was to investigate and quantify the relationship relating laser weld parameters and the vapor capillary (keyhole) through a state-of-the-art measurement technique. Bead-on-plate laser beam welds were produced with partial penetration on 304L stainless steel, 2205 duplex stainless steel, and Ti-6Al-4V. Keyhole monitoring was performed using a commercially available ICI system to collect keyhole penetration data in real time. These measurements were reconstructed to generate the vapor capillary shape at different welding parameters. Process parameters significantly influenced the keyhole shape and the keyhole root position relative to the process beam. The keyhole geometry showed distinct differences between the stainless steel alloys and Ti-6Al-4V.

Utilisation of the X-ray emission of an electron beam capillary for visualisation of the beam-material interaction

Abstract Both processes, laser beam welding and electron beam welding, rely on the deep penetration process with the typical metal vapour capillary to achieve welds with in-creasing weld-in depths. With both processes, the capillary is the result of a highly dynamic equilibrium of various opposing forces and influences. To increase the understanding of the fluid-dynamic processes inside and around the vapour capillary, methods are needed for the supervision of the process that can deliver geometrical information with high spatial and temporal resolution and especially from the deeper capillary regions. Gaining this insight will allow the implementation of highly dynamic processes in future capillary models as well as the extension of process windows of the beam welding processes.

Preliminary investigation on the transient hygrothermal analysis of a CLT-based retrofit solution for exterior walls

This paper investigates the transient hygrothermal performance of an innovative energy and seismic renovation solution for reinforced concrete (RC) framed buildings, based on the addition of Cross-Laminated Timber (CLT) panels to the outer walls, in combination with wood-based insulation. This solution is being developed in the framework of a four-year EU-funded project called e-SAFE. The investigation relies on numerical simulations in DELPHIN 6.1, by considering combined heat and mass transfer (HAMT) due to water vapour diffusion and capillary transport. The proposed solution is tested in three different climates in Italy, to verify whether the CLT layer and the outer waterproof vapour-open membrane, inserted to protect the wood-based insulation from rain, still allow the effective drying of the vapour accumulated in liquid form in the walls, while also preventing mould formation. The results show that the increased thermal resistance of the wall assembly significantly reduces the total water content, although moderate risks of mould growth in the wooden materials may occur in coldest climates.

Mesoscale modeling of metal-based selective laser melting: evolution of the vapor capillary

In this work we apply a multiphysics approach to selective laser melting to model the evolution of the vapor capillary, taking into account the effects of variable laser intensity, scan speed, and spot size. Restricting the work to a single line scan with a continuous wave laser, we focused on the application of Ti-6Al-4V alloy. In addition to heat, momentum and mass transfer, the solid/liquid/vapor interface was simulated using a front-tracking, level-set method, and an imposed recoil pressure was used to model the evolving vapor capillary. Initial benchmark applications focusing on an evolving melting front served to validate the heat transfer/phase change numerical framework.

Influence of the beam oscillation pattern and oscillation frequency on the temperature field in laser brazing with keyhole formation

Laser keyhole brazing is an opportunity to increase the process efficiency in laser brazing processes. Using small spot sizes increases the intensity and leads to the formation of a vapour capillary (keyhole) in the brazing material when a material-specific threshold value is exceeded. Due to multiple reflections/absorptions of the laser beam in the keyhole, the process efficiency increases in comparison with conventional brazing processes with single Fresnel absorption on the surface, especially when using high-reflectivity braze materials, such as aluminium-based or copper-based alloys. The energy must be distributed adequately by applying beam oscillation transversal to the brazing direction. In laser brazing processes, the temperature field in the interface between brazing and substrate material is a major factor. To analyse the effect of beam oscillation, it is assumed in this study that the temperature distribution at the surface of the melt pool is a suitable approximation for the temperature distribution at the interface to the substrate. Two key parameters are defined to quantify the temperature field referring to the homogeneity: the temporal local temperature-time curve and the temperature distribution transverse to the brazing direction. While the oscillation frequency influences the first mentioned parameter by decreasing the time interval between the local laser passes, the oscillation pattern affects the second parameter by adjusting the local actual beam velocity and its consistency.

An Experimental Approach for the Direct Measurement of Temperatures in the Vicinity of the Keyhole Front Wall during Deep-Penetration Laser Welding

The formation of defects such as pores during deep-penetration laser welding processes is governed by the melt pool dynamics and the stability of the vapor capillary, also referred to as the keyhole. In order to gain an insight into the dynamics of the keyhole, the temperature in the transition region from the liquid to the gaseous phase, i.e., near the keyhole wall, is a physical value of fundamental importance. In this paper, a novel method is presented for directly measuring temperatures in the close vicinity of the keyhole front wall during deep-penetration laser welding. The weld samples consist of pure aluminum with a boiling point of 2743 K. The measurement is performed using high-speed pyrometry with a refractory tantalum probe capable of detecting temperatures that significantly exceed the boiling point of the sample material. Temperature curves are recorded from the beginning of the welding process until the moment the probe is finally destroyed through direct laser-tantalum interaction. With an effective spatial resolution up to 0.3 µm in the welding direction, a detailed investigation into the temperature ranging from the prerunning melt pool front to the keyhole center is possible, exhibiting temperatures of up to 3300 K in the vicinity of the keyhole front wall.