Influence of Surface Structured Filler Wires on Laser Beam Welding of Copper Alloys

2015 ◽  
Vol 805 ◽  
pp. 171-179 ◽  
Author(s):  
Vincent Mann ◽  
Fabian Gärtner ◽  
Florian Hugger ◽  
Konstantin Hofmann ◽  
Felix Tenner ◽  
...  
Keyword(s):  
Energy Efficiency ◽  
Laser Beam ◽  
Weld Seam ◽  
Copper Alloys ◽  
Laser Beam Welding ◽  
Welding Process ◽  
Industrial Applications ◽  
Additional Amount ◽  
Infrared Wavelengths ◽  
Welding Processes

Compared to steel, the required amount of energy for conventional welding of copper is higher, due to its higher thermal conductivity. This problem is mainly solved by preheating the work pieces or welding processes with high intensities such as laser beam welding. As the absorption of copper for infrared wavelengths, which are commonly used in industrial applications today, is typically low, the energy efficiency of the laser welding process is low. Besides this, if filler wires are used in order to increase the bridgeable width of joining gaps, the energy consumption of the process is further increased due to the additional amount of energy required to melt the filler material.As roughened surfaces of copper parts are known to increase absorption and consequently energy efficiency of laser beam welding without filler wires, this paper investigates the influence of surface structured filler wires on laser beam welding of copper alloys. Thus, the correlation between knurling geometries, absorption, molten volume and the welding result is investigated. For this reason, the welding result is evaluated by means of geometrical, electrical and mechanical weld seam properties e.g. seam width, weld reinforcement, area of cross-section, electrical resistance, tensile strength and strain.

Evaluation of High Penetration Hybrid Laser-GMAW Welding Process Productivity Applied in the Joining of Thick Plates and Pipelines

2022 ◽  
Author(s):  
Rafael Gomes Nunes Silva ◽  
Max Baranenko Rodrigues ◽  
Milton Pereira ◽  
Koen Faes
Keyword(s):  
Laser Beam ◽  
Arc Welding ◽  
Manufacturing Industry ◽  
Operating Time ◽  
Laser Beam Welding ◽  
Welding Process ◽  
Major Influence ◽  
Thick Plates ◽  
High Penetration ◽  
Welding Processes

Abstract Welding processes are present in all sectors of the industry, highlighting the manufacturing industry of thick plates and pipelines. In these applications, welding processes have a major influence on costs, schedules, risk analysis and project feasibility. Conventional arc welding processes, such as the gas metal arc welding (GMAW) process, have limitations when applied to high thickness joints due to their maximum achievable penetration depth. On the other hand, the laser beam welding (LBW) welding process, despite reaching high penetration depths, has several limitations mainly regarding the geometric tolerance of the joint. In this regard, the hybrid laser-arc welding (HLAW) process emerges as a promising bonding process, combining the advantages of the GMAW and LBW processes into a single melting pool. Despite the many operational and metallurgical advantages, the HLAW process presents a high complexity due to the high number of parameters involved and the interaction between the laser beam and the electric arc. The present work discusses the challenges involved in the parametrization of the HLAW process applied to the joining of thick plates and pipes, and empirically evaluated a comparison between the HLAW and GMAW processes, showing a reduction of operating time of approximately 40 times, and a reduction of consumption of shielding gas and filler material of approximately 20 times, evidencing the technical and financial contribution of the hybrid process.

Dissimilar and Similar Laser Beam and GTA Welding of Nuclear Fuel Pin Cladding Tube to End Plug Joint

2017 ◽  
Vol 24 ◽  
pp. 40-47
Author(s):  
Aravind Murugan ◽  
R. Sai Santhosh ◽  
Ravikumar Raju ◽  
A.K. Lakshminarayanan ◽  
Shaju K. Albert
Keyword(s):  
Laser Beam ◽  
Laser Welding ◽  
Laser Beam Welding ◽  
Welding Process ◽  
High Energy ◽  
Optical Microscope ◽  
High Energy Density ◽  
Fuel Pin ◽  
Gtaw Process ◽  
Welding Processes

The end plug to cladding tube of fast reactor fuel pin is normally welded using Gas Tungsten Arc Welding (GTAW) process. The GTAW process has large heat input and wide heat-affected-zone (HAZ) than high energy density process such as laser welding. In the present study Laser Beam Welding (LBW) is being considered as an alternative welding process to join end plug to clad tube. The characteristics of autogenous processes such as GTAW and pulsed Nd-YAG laser welding on fuel cladding tube to end plug joints have been investigated in this study. Dissimilar combinations of modified stainless steel (SS) alloy D9 cladding tube to SS316L end plug, and similar combinations of SS316L cladding tube to SS316L end plug were successfully welded using the above two welding processes. The laser welding was performed at the butting surfaces of the cladding tube and the end plug, and also by shifting the laser beam by 0.2 mm towards the end plug side to compensate the heat balance and for improving the Creq/Nieq ratio in the molten pool. Helium Leak Test (HLT) and Radiography Test (RT) were carried out to validate the quality of the welds. The microstructures of the weld joints were analysed using optical microscope. In the present study, it has been demonstrated that it is possible to obtain welds free from hot cracks by shifting the laser beam by 0.2 mm towards end plug side, while the weld produced using the beam positioned at the interface shows cracks in the weld.

scholarly journals Extension of the process limits in laser beam welding of thick-walled components using the Laser Multi-Pass Narrow-Gap welding (Laser-MPNG) on the example of the nickel-based material Alloy 617 occ

2021 ◽  
Author(s):  
Benjamin Kessler ◽  
Dirk Dittrich ◽  
Berndt Brenner ◽  
Jens Standfuss ◽  
Christoph Leyens
Keyword(s):  
Laser Beam ◽  
Low Cycle Fatigue ◽  
Laser Beam Welding ◽  
Welding Process ◽  
Industrial Applications ◽  
Fatigue Tests ◽  
Narrow Gap ◽  
Narrow Gap Welding ◽  
Alloy 617 ◽  
First Time

AbstractThe joining of thick-walled components using beam-based joining techniques is content of worldwide research and development activities, but has not yet been established in industry. State of the art to weld nickel super alloys is currently a TIG narrow-gap welding. The present paper is focusing on a new specific laser beam welding process, the so-called Laser Multi-Pass Narrow-Gap welding (Laser-MPNG). It first explains the process principle based on 2D beam oscillation, the use of fiber lasers and the multi-pass principle. The potential of the Laser-MPNG welding process is demonstrated using the technically significant nickel-based material Alloy 617 occ. As a result, it was possible for the first time to realize a weld with a wall thickness of 140 mm free of cracks or bonding defects. Promising results of creep and low-cycle fatigue tests are used to show the potential that Laser-MPNG welded joints would have for future industrial applications.

scholarly journals Laser welding of current collector foil stacks in battery production–mechanical properties of joints welded with a green high-power disk laser

2021 ◽  
Author(s):  
Sophie Grabmann ◽  
Johannes Kriegler ◽  
Felix Harst ◽  
Florian J. Günter ◽  
Michael F. Zaeh
Keyword(s):  
Laser Beam ◽  
Lithium Ion Batteries ◽  
Process Parameters ◽  
High Power ◽  
Weld Seam ◽  
Production Systems ◽  
Laser Beam Welding ◽  
Welding Process ◽  
Lithium Ion ◽  
Current Collector

AbstractThe qualification of production systems that enable reliable and stable production processes is a major challenge in manufacturing large-format lithium-ion batteries. During cell assembly, the electrode sheets of the anode and the cathode are stacked, and are electrically contacted by a welding process. It was shown that laser beam welding employing a beam source in the green wavelength range is a promising joining approach in terms of high productivity. Therefore, the influence of the process parameters, such as the laser power, the welding speed, the pulse frequency, and the pulse duration, on the weld seam quality was investigated. Particular emphasis was placed on the mechanical strength of the weld seam. Statistically planned experiments were used to determine feasible parameter sets for welding the most common current collectors of lithium-ion battery electrodes, copper (Cu), and aluminum (Al). The influence of the individual process parameters on the tensile shear force was evaluated. Stacks of 40 metal foils were welded with a thin metal sheet in lap joint configuration. Based on an analysis of the requirements for minimum mechanical seam strengths, this study confirms that laser beam welding using a green high-power disk source is an auspicious process for the internal contacting of lithium-ion batteries.

scholarly journals Development of laser welding of high strength aluminium alloy 2024-T4 with controlled thermal cycle

2020 ◽  
Vol 326 ◽  
pp. 08005
Author(s):  
Mete Demirorer ◽  
Wojciech Suder ◽  
Supriyo Ganguly ◽  
Simon Hogg ◽  
Hassam Naeem
Keyword(s):  
Laser Beam ◽  
Laser Welding ◽  
Heat Input ◽  
Thermal Cycle ◽  
Laser Beam Welding ◽  
Base Material ◽  
High Strength ◽  
Cooling Rates ◽  
Aa 2024 ◽  
Welding Processes

An innovative process design, to avoid thermal degradation during autogenous fusion welding of high strength AA 2024-T4 alloy, based on laser beam welding, is being developed. A series of instrumented laser welds in 2 mm thick AA 2024-T4 alloys were made with different processing conditions resulting in different thermal profiles and cooling rates. The welds were examined under SEM, TEM and LOM, and subjected to micro-hardness examination. This allowed us to understand the influence of cooling rate, peak temperature, and thermal cycle on the growth of precipitates, and related degradation in the weld and heat affected area, evident as softening. Although laser beam welding allows significant reduction of heat input, and higher cooling rates, as compared to other high heat input welding processes, this was found insufficient to completely supress coarsening of precipitate in HAZ. To understand the required range of thermal cycles, additional dilatometry tests were carried out using the same base material to understand the time-temperature relationship of precipitate formation. The results were used to design a novel laser welding process with enhanced cooling, such as with copper backing bar and cryogenic cooling.

Possibilities to Apply Friction Stir Processing FSP in Surface Engineering

2021 ◽  
Vol 890 ◽  
pp. 56-65
Author(s):  
Cristian Ciucă ◽  
Lia Nicoleta Boțilă ◽  
Radu Cojocaru ◽  
Ion Aurel Perianu
Keyword(s):  
Aluminum Alloys ◽  
Friction Stir Processing ◽  
Surface Engineering ◽  
Copper Alloys ◽  
Welding Process ◽  
Industrial Applications ◽  
Process Conditions ◽  
Cast Aluminum ◽  
Friction Stir ◽  
Cast Aluminum Alloys

The results obtained by ISIM Timisoara to the development of the friction stir welding process (FSW) have supported the extension of the researches on some derived processes, including friction stir processing (FSP). The experimental programs (the researches) were developed within complex research projects, aspects regarding the principle of the process, modalities and techniques of application, experiments for specific applications, being approached. The paper presents good results obtained by friction stir processing of cast aluminum alloys and copper alloys. The optimal process conditions, optimal characteristics of the processing tools were defined. The complex characterization of the processed areas was done, the advantages of the process applying being presented, especially for the cast aluminum alloys: EN AW 4047, EN AW 5083 and EN AW 7021. The characteristics of the processed areas are compared with those of the base materials. The results obtained are a solid basis for substantiating of some specific industrial applications, especially in the automotive, aeronautical / aerospace fields.

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