Laser Beam Welding
Laser Beam Welding
Laser Beam Welding
The beam provides a concentrated heat source, allowing for narrow, deep welds and high welding rates. The process is frequently used in high volume applications, such as in the automotive industry.
Operation
Like electron beam welding (EBW), laser beam welding has high power density (on the order of 1 MW/cm2) resulting in small heat-affected zones and high heating and cooling rates. The spot size of the laser can vary between 0.2 mm and 13 mm, though only smaller sizes are used for welding. The depth of penetration is proportional to the amount of power supplied, but is also dependent on the location of the focal point: penetration is maximized when the focal point is slightly below the surface of the workpiece A continuous or pulsed laser beam may be used depending upon the application. Millisecondlong pulses are used to weld thin materials such as razor blades while continuous laser systems are employed for deep welds. LBW is a versatile process, capable of welding carbon steels, HSLA steels, stainless steel, aluminum, and titanium. Due to high cooling rates, cracking is a concern when welding highcarbon steels. The weld quality is high, similar to that of electron beam welding. The speed of welding is proportional to the amount of power supplied but also depends on the type and thickness of the workpieces. The high power capability of gas lasers make them especially suitable for high volume applications. LBW is particularly dominant in the automotive industry.[1][2] Some of the advantages of LBW in comparison to EBW are as follows: - the laser beam can be transmitted through air rather than requiring a vacuum, - the process is easily automated with robotic machinery, - x-rays are not generated, and - LBW results in higher quality welds. A derivative of LBW, laser-hybrid welding, combines the laser of LBW with an arc welding method such as gas metal arc welding. This combination allows for greater positioning flexibility, since GMAW supplies molten metal to fill the joint, and due to the use of a laser, increases the welding speed over what is normally possible with GMAW. Weld quality tends to be higher as well, since the potential for undercutting is reduced.[3]
Equipment
The two types of lasers commonly used are solid-state lasers and gas lasers (especially ruby lasers and Nd:YAG lasers). The first type uses one of several solid media, including synthetic ruby and chromium in aluminum oxide, neodymium in glass (Nd:glass), and the most common type, crystal composed of yttrium aluminum garnet doped with neodymium (Nd:YAG). Gas lasers use mixtures of gases like helium, nitrogen, and carbon dioxide (CO2 laser) as a medium. Regardless of type, however, when the medium is excited, it emits photons and forms the laser beam.
Gas laser
Gas lasers use high-voltage, low-current power sources to supply the energy needed to excite the gas mixture used as a lasing medium. These lasers can operate in both continuous and pulsed mode, and the wavelength of the laser beam is 10.6 m. Fiber optic cable absorbs and is destroyed by this wavelength, so a rigid lens and mirror delivery system is used. Power outputs for gas lasers can be much higher than solid-state lasers, reaching 25 kW.[4]
Fiber laser
In fiber lasers, the gain medium is the optical fiber itself. They are capable of power up to 50 kW and are increasingly being used for robotic industrial welding.