Mitigation of Root Defect in Laser and Hybrid LaserArc Welding.pdfVIP

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Mitigation of Root Defect in Laser and Hybrid LaserArc Welding.pdf

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Mitigation of Root Defect in Laser and Hybrid LaserArc Welding

WELDING RESEARCH MARCH 2015 / WELDING JOURNAL 73-s Introduction High-power laser and hybrid laser- arc welding (Refs. 1– 5) offer faster welding speeds, lower heat inputs, and deeper penetration over traditional arc welding processes in a range of differ- ent construction and fabrication in- dustries (Ref. 6). However, these processes are also susceptible to unique defects associated with their high aspect ratio and deep penetra- tion. Two of the most common of these defects include porosity from keyhole instability in partial-penetra- tion welds (Refs. 7–9) and complete- joint-penetration welding root defects. The latter defect has also been called chain of pearls (Ref. 10), dropping (Ref. 11), and root humping (Ref. 12). and is characterized by the formation of weld metal spheroids at the bottom surface of a complete-joint-penetra- tion weld. An example of root defects in a DH36 steel hybrid laser-arc weld is shown in Fig. 1A. As higher laser pow- ers become available and deeper pene- trations are obtained, these defects will become more problematic, and a deeper understanding of the mecha- nisms driving these defects will be necessary to take advantage of these high laser powers. Root defects have been character- ized at both high (Refs. 13–16) and low (Refs. 11, 13, 17, 18) heat inputs. Consequently, changes in laser power or welding speed resulted in the ap- pearance or disappearance of root de- fects. For example, in 304 stainless steel, Zhang et al. (Ref. 14) and Kaplan and Wiklund (Ref. 16) found that root defects occur at lower welding speeds (i.e., higher heat input) during laser welding of 12- and 16-mm-thick plates, respectively. In other cases, in- creasing the heat input leads to accept- able welds. Havrilla et al. (Ref. 11) in- creased the laser power by 1 kW from 7.75 to 8.75 kW at a constant welding speed to eliminate root defects in 12- mm-thick steel. Ilar et al. (Ref. 12) em- ployed high-speed imaging to study the formation of root defe