Analysis of the laser welding keyhole using inline coherent imaging

Journal Article · Wed Aug 24 00:00:00 EDT 2022 · Journal of Manufacturing Processes

DOI:https://doi.org/10.1016/j.jmapro.2022.08.009· OSTI ID:1957744

Patterson, Tate ^[1]; Panton, Boyd ^[2]; Lippold, John C. ^[2]

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1. Idaho National Lab. (INL), Idaho Falls, ID (United States)
2. The Ohio State Univ., Columbus, OH (United States)

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. Finally, the keyhole geometry showed distinct differences between the stainless steel alloys and Ti-6Al-4V.

• Research Organization: Idaho National Laboratory (INL), Idaho Falls, ID (United States)
• Sponsoring Organization: National Science Foundation (NSF); USDOE Office of Nuclear Energy (NE)
• Grant/Contract Number: AC07-05ID14517
• OSTI ID: 1957744
• Report Number(s): INL/JOU-23-71080-Rev000
• Journal Information: Journal of Manufacturing Processes, Journal Name: Journal of Manufacturing Processes Vol. 82; ISSN 1526-6125
• Publisher: Society of Manufacturing Engineers; Elsevier
• Country of Publication: United States
• Language: English

Related Subjects

2205
304L
36 MATERIALS SCIENCE
42 ENGINEERING
47 OTHER INSTRUMENTATION
Ti-6Al-4V
inline coherent imaging
laser beam welding
weld penetration