In order to obtain a high-quality weld during the laser welding process, extracting the characteristic parameters of weld pool is an important issue for automated welding. In this paper, the type 304 austenitic stainl...In order to obtain a high-quality weld during the laser welding process, extracting the characteristic parameters of weld pool is an important issue for automated welding. In this paper, the type 304 austenitic stainless steel is welded by a 5 kW high-power fiber laser and a high-speed camera is employed to capture the topside images of weld pools. Then we propose a robust visual-detection approach for the molten pool based on the supervised descent method. It provides an elegant framework for representing the outline of a weld pool and is especially efficient for weld pool detection in the presence of strong uncertainties and disturbances. Finally, welding experimental results verified that the proposed approach can extract the weld pool boundary accurately, which will lay a solid foundation for controlling the weld quality of fiber laser welding process.展开更多
A visual sensing system was established to monitor the weld pool in laser spot welding. The top-hat and bottom-hat transformation algorithms based on mathematical morphology were used to compensate for non-uniform con...A visual sensing system was established to monitor the weld pool in laser spot welding. The top-hat and bottom-hat transformation algorithms based on mathematical morphology were used to compensate for non-uniform contrast of weld pool edge. Moreover, the canny edge detector was applied to extract the weld paol profile. The edge detected results show that the morphological operation is obviously superior to the traditional contrast enhancement method. In addition, the combination of dilation and erosion was applied to eliminate the irrelevant edge details, and the smooth weld pool edge was acquired. Based on the image processing technology described above, the dynamic process of weld pool diameter during laser spot welding was obtained.展开更多
An experimental setup of acquiring the coaxial visual image of the molten pool and keyhole in high power Nd:YAG laser welding is introduced in this paper. It is one of the most difficult problems in acquiring coaxial ...An experimental setup of acquiring the coaxial visual image of the molten pool and keyhole in high power Nd:YAG laser welding is introduced in this paper. It is one of the most difficult problems in acquiring coaxial image that the coaxial imaging signal of molten pool and keyhole must be separated from the laser beam with high power. This problem was resolved by designing a dichroitic spectroscope. The characteristics of imaging signal were analyzed and the coaxial image of molten pool and keyhole was acquired. A smoothing filter and a homomorphic filter were designed to remove the low frequency noise and to enhance the image according to the characteristics of imaging signal. At last, edges of molten pool and keyhole were detected and extracted based on image segmentation with threshold.展开更多
The main characteristic feature of deep penetration laser beam welding is a large temperature difference between the plasma cavity(keyhole)in the weld pool centre and the melting/solidification front.Large temperature...The main characteristic feature of deep penetration laser beam welding is a large temperature difference between the plasma cavity(keyhole)in the weld pool centre and the melting/solidification front.Large temperature gradients in the weld pool result in very intensive thermocapillary(Marangoni)convection.The weld pool surface width becomes very large and unstable.However,an externally applied oscillating magnetic field can stabilize the surface of the melt.In the present work this technology was used to stabilize the weld pool surface in partial penetration 4.4 kW Nd:YAG laser beam welding of AW-5754 aluminium alloy in PA position.An AC magnet was mounted on the laser welding head.The oscillating magnetic field was oriented perpendicular to the welding direction.It was found that the AC magnetic field can drastically reduce the surface roughness of welds.X-ray image analysis shows a drastic reduction of welds porosity.This effect can be explained as a result of electromagnetic rectification of the melt.展开更多
Two measuring methods, high-speed camera and optical monitoring system, were used to study processes of laser welding. Molten pool, cooling time and temperature field were analyzed based on real measured images and op...Two measuring methods, high-speed camera and optical monitoring system, were used to study processes of laser welding. Molten pool, cooling time and temperature field were analyzed based on real measured images and optical signal data. The results show that the width of molten pool is almost equal to the width of weld, and length is about 7. 8 mm. The solidification time is about 0. 5 s and the temperature gradient is great, so HAZ is very small. The method and results will be of benefit to build the relationship between welding parameters and microstructure.展开更多
The effect of the laser processing parameters on the composition uniformity and shape coefficient of fusion zone with laser surface alloyed Cr plated on medium carbon low alloy steel has been studied.It was found that...The effect of the laser processing parameters on the composition uniformity and shape coefficient of fusion zone with laser surface alloyed Cr plated on medium carbon low alloy steel has been studied.It was found that the composition uniformity depends on the shape coefficient of fusion zone,and the later is a function of both power density and interaction time.If the power density is fixed to a certain value,the shape coefficient is directly,propor- tional to the interaction time.A completely,uniform molten pool can be obtained,when the shape coefficient is between 1.6 and 3.0.展开更多
The laser remelting with a two-layer material system (upper material was Al-30 % Ti-20 % Ni alloy,substrate was commercial aluminum alloy) and the laser cladding of a commercial 45 steel with copper Powder (including ...The laser remelting with a two-layer material system (upper material was Al-30 % Ti-20 % Ni alloy,substrate was commercial aluminum alloy) and the laser cladding of a commercial 45 steel with copper Powder (including 25%SiC) were carried out using a 2kW continuous CO2 laser. For the case of laser remelting, a upper Pool in the alloying layer and a lower Pool in the substrate separated by the unmelted Al-Ti-Ni alloy were observed. For laser cladding, a stratified Pool was observed, whose top layer was Cu alloy liquid and bottom was Fe alloy liquid. The mechanism of laser Pool separation and stratification is illustrated by numerical calculation of heat transter process of the two-layer system, combining with material physical properties (especially mixed enthalpy). A classification criterion for laser Pool with the two-layer material system has been presented and four types of the laser Pool are divided into unique Pool, separated Pool, mixed Pool and stratified pool,which provides a theoretical basis for obtaining a excellent surface coating.展开更多
Laser welding is one of high efficiency, high energy density welding methods. Quality control should be applied to ensure good welding quality. Weld pool and keyhole contains abundant information of welding quality. G...Laser welding is one of high efficiency, high energy density welding methods. Quality control should be applied to ensure good welding quality. Weld pool and keyhole contains abundant information of welding quality. Good image processing algorithm is necessary in quality control system based on visual sensing. Aiming at the image captured by a coaxial visual sensing system for laser welding, an image processing algorithm is designed. An edge predicting method is proposed in image processing algorithm which is based on the fact that the local shape of weld pool can be fitted to a circle. The results show that the algorithm works well. It lays solid foundation for further quality control in laser welding.展开更多
A three-dimensional laminar steady state numerical model was used to investigate the influence of an alternating current(ac)magnetic field during single pass high power laser beam keyhole welding of 20 mm thick alumin...A three-dimensional laminar steady state numerical model was used to investigate the influence of an alternating current(ac)magnetic field during single pass high power laser beam keyhole welding of 20 mm thick aluminum.The three-dimensional heat transfer,fluid dynamics and electromagnetic field equations were solved with the commercial finite element package COMSOL Multiphysics.Dominant physical effects of the process were taken into account:Thermo-capillary(Marangoni)convection at the upper and lower weld pool surfaces,natural convection due to the gravity influence and the latent heat of solid-liquid phase transition.Simulations were conducted for several magnetic field strengths and it was found that the gravity drop-out associated with welding of thick plates due to the hydrostatic pressure can be prevented by the application of an ac magnetic field below the weld specimen of around 70 mT(rms)at an oscillation frequency of 450 Hz.The inductive support system allows for single-pass laser beam welding of thick aluminum plates.The flow pattern in the molten zone and the temperature distributions are significantly changed by the application of the electromagnetic forces in the weld pool.展开更多
A mathematical model was established to simulate the weld pool development and dynamic process in stationary iaser-MlG hybrid welding. Surface tension and buoyancy were considered to calculate liquid metal flow patter...A mathematical model was established to simulate the weld pool development and dynamic process in stationary iaser-MlG hybrid welding. Surface tension and buoyancy were considered to calculate liquid metal flow patter, moreover, typical phenomena of MIG welding, such as filler droplets impinging weld pool, electromagnetic force in the weld pool, and typical phenomena of laser beam welding, such as recoil pressure, Inverse Bremsstrahlung absorption, Fresnel absorption were all considered in the model. The laser beam and arc couple effect were introduced into this model by the plasma width during hybrid welding. The role of recoil pressure in the weld formation was discussed. Transient weld pool shape and complicated liquid metal velocity distribution from two kinds weld pool to an unified weld pool were calculated. The simulated weld bead geometry with consideration recoil pressure was in good agreement with experimental measurement.展开更多
This article presents the microstructure and hardness variation of an Al 8.5Fe-1.3V 1.7Si （wt%, FVS0812） alloy after selective laser melting （SLM） modification. Three zones were distinguished across the melting po...This article presents the microstructure and hardness variation of an Al 8.5Fe-1.3V 1.7Si （wt%, FVS0812） alloy after selective laser melting （SLM） modification. Three zones were distinguished across the melting pool of the SLM-processed FVS0812 alloy： the laser melted zone （LMZ）, the melting pool border, and the heat affected zone （HAZ） in the previously deposited area around the melting pool. Inside the LMZ, either an extremely fine cellular-dendritic structure or a mixture zone of the α-Al matrix and nanoscale Al12（Fe,V）3Si particles appeared. With a decreased laser beam scanning speed, the cellular-dendritic structure zone within the LMZ shrank significantly while the mixture zone expanded. The α-Al and Al12（Fe,V）3Si mixture zone was also observed in the HAZ, but another phase, submicron θ-Al13Fe4 particles with rectangular or hexagonal shapes, formed along the melting pool border. Microhardness tests indicated that the hardness of the SLM-processed FVS0812 samples far exceeded that of the as-cast FVS0812 alloy.展开更多
Selective laser melting（SLM） was employed to fabricate Nb-37 Ti-13 Cr-2 Al-1 Si（at%）alloy, using pre-alloyed powders prepared by plasma rotating electrode processing（PREP）. A series of single tracks and single l...Selective laser melting（SLM） was employed to fabricate Nb-37 Ti-13 Cr-2 Al-1 Si（at%）alloy, using pre-alloyed powders prepared by plasma rotating electrode processing（PREP）. A series of single tracks and single layers under different processing parameters was manufactured to evaluate the processing feasibility by SLM, including laser power, scanning speed, and hatch distance.Results showed that continuous single tracks could be fabricated using proper laser powers and scanning velocities. Both the width of a single track and its penetration depth into a substrate increased with an increase of the linear laser beam energy density（LED）, i.e., an increase of the laser power and a decrease of the scanning speed. Nb, Ti, Si, Cr, and Al elements distributed heterogeneously over the melt pool in the form of swirl-like patterns. An excess of the hatch distance was not able to interconnect neighboring tracks. Under improper processing parameters, a balling phenomenon occurred, but could be eliminated with an increased LED. This work testified the SLMprocessing feasibility of Nb-based alloy and promoted the application of SLM to the manufacture of niobium-based alloys.展开更多
Based on the extended application of COMSOL multiphysics, a novel dual heat source model for pulsed laser-gas tungsten arc （GTA） hybrid welding was established. This model successfully solved the problem of simulati...Based on the extended application of COMSOL multiphysics, a novel dual heat source model for pulsed laser-gas tungsten arc （GTA） hybrid welding was established. This model successfully solved the problem of simulation inaccuracy caused by energy superposition effect between laser and arc due to their different physical characteristics. Numerical simulation for pulsed laser-GTA hybrid welding of magnesium alloy process was conducted, and the simulation indicated good agree- ments with the measured thermal cycle curve and the shape of weld beads. Effects of pulse laser parameters （laser-excited current, pulse duration, and pulse frequency） on the temperature field and weld pool morphology were investigated. The experimental and simulation results suggest that when the laser pulse energy keeps constant, welding efficiency of the hybrid heat source is increased by increasing laser current or decreasing pulse duration due to the increased ratio of the weld bead depth to width. With large laser currents, severe spatters tend to occur. For optimized welding process, the laser current should be controlled in the range of 150-175 A, the pulse duration should be longer than 1 ms, and the pulse frequency should be equal to or slightly greater than 20 Hz.展开更多
The corrosion behavior and mechanical properties of 316 L stainless steel(SS) fabricated via selective laser melting(SLM) were clarified by potentiodynamic polarization measurements, immersion tests, and tensile exper...The corrosion behavior and mechanical properties of 316 L stainless steel(SS) fabricated via selective laser melting(SLM) were clarified by potentiodynamic polarization measurements, immersion tests, and tensile experiments. The microstructural anisotropy of SLMed 316 L SS was also investigated by electron back-scattered diffraction and transmission electron microscopy. The grain sizes of the SLMed 316 L SS in the XOZ plane were smaller than those of the SLMed 316 L SS in the XOY plane, and a greater number of low-angle boundaries were present in the XOY plane, resulting in lower elongation for the XOY plane than for the XOZ plane. The SLMed 316 L was expected to exhibit higher strength but lower ductility than the wrought 316 L, which was attributed to the high density of dislocations. The pitting potentials of the SLMed 316 L samples were universally higher than those of the wrought sample in chloride solutions because of the annihilation of MnS or(Ca,Al)-oxides during the rapid solidification. However, the molten pool boundaries preferentially dissolved in aggressive solutions and the damage of the SLMed 316 L in FeCl3 solution was more serious after long-term service, indicating poor durability.展开更多
基金Project was supported by the National Key R&D Program of China(Grant No.2017YFB1104404)
文摘In order to obtain a high-quality weld during the laser welding process, extracting the characteristic parameters of weld pool is an important issue for automated welding. In this paper, the type 304 austenitic stainless steel is welded by a 5 kW high-power fiber laser and a high-speed camera is employed to capture the topside images of weld pools. Then we propose a robust visual-detection approach for the molten pool based on the supervised descent method. It provides an elegant framework for representing the outline of a weld pool and is especially efficient for weld pool detection in the presence of strong uncertainties and disturbances. Finally, welding experimental results verified that the proposed approach can extract the weld pool boundary accurately, which will lay a solid foundation for controlling the weld quality of fiber laser welding process.
文摘A visual sensing system was established to monitor the weld pool in laser spot welding. The top-hat and bottom-hat transformation algorithms based on mathematical morphology were used to compensate for non-uniform contrast of weld pool edge. Moreover, the canny edge detector was applied to extract the weld paol profile. The edge detected results show that the morphological operation is obviously superior to the traditional contrast enhancement method. In addition, the combination of dilation and erosion was applied to eliminate the irrelevant edge details, and the smooth weld pool edge was acquired. Based on the image processing technology described above, the dynamic process of weld pool diameter during laser spot welding was obtained.
文摘An experimental setup of acquiring the coaxial visual image of the molten pool and keyhole in high power Nd:YAG laser welding is introduced in this paper. It is one of the most difficult problems in acquiring coaxial image that the coaxial imaging signal of molten pool and keyhole must be separated from the laser beam with high power. This problem was resolved by designing a dichroitic spectroscope. The characteristics of imaging signal were analyzed and the coaxial image of molten pool and keyhole was acquired. A smoothing filter and a homomorphic filter were designed to remove the low frequency noise and to enhance the image according to the characteristics of imaging signal. At last, edges of molten pool and keyhole were detected and extracted based on image segmentation with threshold.
基金Item Sponsored by the German Collaborative Industrial Research Program (IGF) and the German Welding Society (DVS) Under Grant Nr.IGF-17.265 N/DVS-06.078
文摘The main characteristic feature of deep penetration laser beam welding is a large temperature difference between the plasma cavity(keyhole)in the weld pool centre and the melting/solidification front.Large temperature gradients in the weld pool result in very intensive thermocapillary(Marangoni)convection.The weld pool surface width becomes very large and unstable.However,an externally applied oscillating magnetic field can stabilize the surface of the melt.In the present work this technology was used to stabilize the weld pool surface in partial penetration 4.4 kW Nd:YAG laser beam welding of AW-5754 aluminium alloy in PA position.An AC magnet was mounted on the laser welding head.The oscillating magnetic field was oriented perpendicular to the welding direction.It was found that the AC magnetic field can drastically reduce the surface roughness of welds.X-ray image analysis shows a drastic reduction of welds porosity.This effect can be explained as a result of electromagnetic rectification of the melt.
文摘Two measuring methods, high-speed camera and optical monitoring system, were used to study processes of laser welding. Molten pool, cooling time and temperature field were analyzed based on real measured images and optical signal data. The results show that the width of molten pool is almost equal to the width of weld, and length is about 7. 8 mm. The solidification time is about 0. 5 s and the temperature gradient is great, so HAZ is very small. The method and results will be of benefit to build the relationship between welding parameters and microstructure.
文摘The effect of the laser processing parameters on the composition uniformity and shape coefficient of fusion zone with laser surface alloyed Cr plated on medium carbon low alloy steel has been studied.It was found that the composition uniformity depends on the shape coefficient of fusion zone,and the later is a function of both power density and interaction time.If the power density is fixed to a certain value,the shape coefficient is directly,propor- tional to the interaction time.A completely,uniform molten pool can be obtained,when the shape coefficient is between 1.6 and 3.0.
文摘The laser remelting with a two-layer material system (upper material was Al-30 % Ti-20 % Ni alloy,substrate was commercial aluminum alloy) and the laser cladding of a commercial 45 steel with copper Powder (including 25%SiC) were carried out using a 2kW continuous CO2 laser. For the case of laser remelting, a upper Pool in the alloying layer and a lower Pool in the substrate separated by the unmelted Al-Ti-Ni alloy were observed. For laser cladding, a stratified Pool was observed, whose top layer was Cu alloy liquid and bottom was Fe alloy liquid. The mechanism of laser Pool separation and stratification is illustrated by numerical calculation of heat transter process of the two-layer system, combining with material physical properties (especially mixed enthalpy). A classification criterion for laser Pool with the two-layer material system has been presented and four types of the laser Pool are divided into unique Pool, separated Pool, mixed Pool and stratified pool,which provides a theoretical basis for obtaining a excellent surface coating.
文摘Laser welding is one of high efficiency, high energy density welding methods. Quality control should be applied to ensure good welding quality. Weld pool and keyhole contains abundant information of welding quality. Good image processing algorithm is necessary in quality control system based on visual sensing. Aiming at the image captured by a coaxial visual sensing system for laser welding, an image processing algorithm is designed. An edge predicting method is proposed in image processing algorithm which is based on the fact that the local shape of weld pool can be fitted to a circle. The results show that the algorithm works well. It lays solid foundation for further quality control in laser welding.
基金Item Sponsored by the Deutsche Forschungsgemeinschaft (BonnGermany) under Grant No.DFG GU 1211/2-1
文摘A three-dimensional laminar steady state numerical model was used to investigate the influence of an alternating current(ac)magnetic field during single pass high power laser beam keyhole welding of 20 mm thick aluminum.The three-dimensional heat transfer,fluid dynamics and electromagnetic field equations were solved with the commercial finite element package COMSOL Multiphysics.Dominant physical effects of the process were taken into account:Thermo-capillary(Marangoni)convection at the upper and lower weld pool surfaces,natural convection due to the gravity influence and the latent heat of solid-liquid phase transition.Simulations were conducted for several magnetic field strengths and it was found that the gravity drop-out associated with welding of thick plates due to the hydrostatic pressure can be prevented by the application of an ac magnetic field below the weld specimen of around 70 mT(rms)at an oscillation frequency of 450 Hz.The inductive support system allows for single-pass laser beam welding of thick aluminum plates.The flow pattern in the molten zone and the temperature distributions are significantly changed by the application of the electromagnetic forces in the weld pool.
文摘A mathematical model was established to simulate the weld pool development and dynamic process in stationary iaser-MlG hybrid welding. Surface tension and buoyancy were considered to calculate liquid metal flow patter, moreover, typical phenomena of MIG welding, such as filler droplets impinging weld pool, electromagnetic force in the weld pool, and typical phenomena of laser beam welding, such as recoil pressure, Inverse Bremsstrahlung absorption, Fresnel absorption were all considered in the model. The laser beam and arc couple effect were introduced into this model by the plasma width during hybrid welding. The role of recoil pressure in the weld formation was discussed. Transient weld pool shape and complicated liquid metal velocity distribution from two kinds weld pool to an unified weld pool were calculated. The simulated weld bead geometry with consideration recoil pressure was in good agreement with experimental measurement.
基金financially supported by the National Natural Science Foundation of China (No. 51101003)
文摘This article presents the microstructure and hardness variation of an Al 8.5Fe-1.3V 1.7Si （wt%, FVS0812） alloy after selective laser melting （SLM） modification. Three zones were distinguished across the melting pool of the SLM-processed FVS0812 alloy： the laser melted zone （LMZ）, the melting pool border, and the heat affected zone （HAZ） in the previously deposited area around the melting pool. Inside the LMZ, either an extremely fine cellular-dendritic structure or a mixture zone of the α-Al matrix and nanoscale Al12（Fe,V）3Si particles appeared. With a decreased laser beam scanning speed, the cellular-dendritic structure zone within the LMZ shrank significantly while the mixture zone expanded. The α-Al and Al12（Fe,V）3Si mixture zone was also observed in the HAZ, but another phase, submicron θ-Al13Fe4 particles with rectangular or hexagonal shapes, formed along the melting pool border. Microhardness tests indicated that the hardness of the SLM-processed FVS0812 samples far exceeded that of the as-cast FVS0812 alloy.
基金supported by the National Natural Science Foundation of China (Nos. 51471013 and 51571004)
文摘Selective laser melting（SLM） was employed to fabricate Nb-37 Ti-13 Cr-2 Al-1 Si（at%）alloy, using pre-alloyed powders prepared by plasma rotating electrode processing（PREP）. A series of single tracks and single layers under different processing parameters was manufactured to evaluate the processing feasibility by SLM, including laser power, scanning speed, and hatch distance.Results showed that continuous single tracks could be fabricated using proper laser powers and scanning velocities. Both the width of a single track and its penetration depth into a substrate increased with an increase of the linear laser beam energy density（LED）, i.e., an increase of the laser power and a decrease of the scanning speed. Nb, Ti, Si, Cr, and Al elements distributed heterogeneously over the melt pool in the form of swirl-like patterns. An excess of the hatch distance was not able to interconnect neighboring tracks. Under improper processing parameters, a balling phenomenon occurred, but could be eliminated with an increased LED. This work testified the SLMprocessing feasibility of Nb-based alloy and promoted the application of SLM to the manufacture of niobium-based alloys.
基金This work was supported by the Natural Science Foundation of Liaoning Province of China （Grant Nos. 201602391 and 20170540460）.
文摘Based on the extended application of COMSOL multiphysics, a novel dual heat source model for pulsed laser-gas tungsten arc （GTA） hybrid welding was established. This model successfully solved the problem of simulation inaccuracy caused by energy superposition effect between laser and arc due to their different physical characteristics. Numerical simulation for pulsed laser-GTA hybrid welding of magnesium alloy process was conducted, and the simulation indicated good agree- ments with the measured thermal cycle curve and the shape of weld beads. Effects of pulse laser parameters （laser-excited current, pulse duration, and pulse frequency） on the temperature field and weld pool morphology were investigated. The experimental and simulation results suggest that when the laser pulse energy keeps constant, welding efficiency of the hybrid heat source is increased by increasing laser current or decreasing pulse duration due to the increased ratio of the weld bead depth to width. With large laser currents, severe spatters tend to occur. For optimized welding process, the laser current should be controlled in the range of 150-175 A, the pulse duration should be longer than 1 ms, and the pulse frequency should be equal to or slightly greater than 20 Hz.
基金financially supported by the Shanghai Materials Genome Institute No. 5 (No. 16DZ2260605)the Shanghai Sailing Program (No. 17YF1405400)the Project to Strengthen Industrial Development at the Grass-roots Level (No. TC160A310/19)
文摘The corrosion behavior and mechanical properties of 316 L stainless steel(SS) fabricated via selective laser melting(SLM) were clarified by potentiodynamic polarization measurements, immersion tests, and tensile experiments. The microstructural anisotropy of SLMed 316 L SS was also investigated by electron back-scattered diffraction and transmission electron microscopy. The grain sizes of the SLMed 316 L SS in the XOZ plane were smaller than those of the SLMed 316 L SS in the XOY plane, and a greater number of low-angle boundaries were present in the XOY plane, resulting in lower elongation for the XOY plane than for the XOZ plane. The SLMed 316 L was expected to exhibit higher strength but lower ductility than the wrought 316 L, which was attributed to the high density of dislocations. The pitting potentials of the SLMed 316 L samples were universally higher than those of the wrought sample in chloride solutions because of the annihilation of MnS or(Ca,Al)-oxides during the rapid solidification. However, the molten pool boundaries preferentially dissolved in aggressive solutions and the damage of the SLMed 316 L in FeCl3 solution was more serious after long-term service, indicating poor durability.
