铝合金光纤激光及其复合焊接的等离子体行为与工艺研究
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摘要
激光及激光-电弧复合焊接技术由于其突出的优势，必然会在现代工业领域获得广泛的应用。高功率光纤激光由于其优良特性，一经问世就获得了广泛关注，但是由于出现时间较短，相关研究远不如已经发展多年的CO2激光和YAG激光。综合国内外的研究情况可知，虽然工艺探索研究可以使激光及激光-电弧复合焊接技术的应用范围得到拓展，但是对机理认识的缺乏，大大限制了该项技术在工业实际生产中的推广应用。
本文在自行构建的系统平台上，通过系统的铝合金光纤激光及其复合焊接工艺实验，采用高速摄像和光谱仪对等离子体行为进行观测，研究了等离子体对激光能量传输的影响、激光与电弧的相互作用等机理问题；并针对实际应用，对铝合金薄板的光纤激光搭接焊缺陷形成机理和预防措施进行研究。主要研究成果与创新工作如下：
光纤激光焊接铝合金时，等离子体/金属蒸气可以分为两个部分，一部分紧贴小孔，一直存在，但其亮度和体积呈现周期性变化；另一部分浮于熔池的上方，会被侧吹气体吹偏，有一个周期性的长大、脱离熔池并逐渐完全消散的过程。两部分的周期变化基本上是密切同步的，周期为450～600s，侧吹保护气体对等离子体/金属蒸气振荡周期无显著影响。提出了一种新的等离子体/金属蒸气周期振荡机理-小孔和熔池的周期性波动是造成等离子体/金属蒸气周期振荡的主要原因。
光纤激光焊接铝合金时，随着激光功率的增大、焊接速度的减小，等离子体/金属蒸气增大，与它们对焊缝熔深的影响一致，在一定条件下，等离子体/金属蒸气的大小可以反映焊缝熔深大小；等离子体/金属蒸气对激光传输影响不大，甚至可以说对光纤激光是透明的，通过侧吹保护气吹等离子体/金属蒸气的方法对熔深的影响不明显。
对2mm厚5754铝合金进行光纤激光搭接焊工艺研究，发现：采用扩张形扁平喷嘴在合适的工艺参数下，可以获得表面成形良好的焊缝；虽然等离子体/金属蒸气对激光传输影响不大，但是使得部分液态金属飞出熔池，形成飞溅，随着激光功率密度的增大，飞溅增多；产生热裂纹的倾向性较小，只有当焊接速度很低时，才会产生热裂纹，随着激光功率的减小，出现热裂纹的临界焊接速度降低；焊缝中低沸点合金元素Mg烧损很少，焊缝组织晶粒细小，显微硬度略低于母材，没有明显的接头软化，焊接接头具有良好的抗拉剪性能。
发现铝合金激光搭接焊时，会形成一种不同于冶金（氢）气孔和工艺气孔的特殊孔洞-夹层孔洞，尺寸较大、形状不规则，且多有锐角出现，往往内部含有黑色氧化物质。这是由于搭接焊时，上、下两层板之间夹层中存在难熔氧化膜引起的，这种因搭接焊的特殊性而形成的独特气孔对焊接接头力学性能影响很大，通过化学清洗或者机械加工方法清除氧化膜能够有效减少夹层气孔的产生，使焊接接头力学性能大大提高。
提出一种新的复合等离子体模型：在焊丝端部到小孔之间会形成一个复合等离子体通道，由A和B两部分组成：A部分来源于单激光等离子体/金属蒸气，但是在体积和亮度上都有很大增强；B部分来源于单MIG电弧，但是方向上发生了很大偏转。通过该模型阐释了激光光致等离子体/金属蒸气与电弧的相互作用机理。
It will be widely applied in the modern industrial fields due to prominent advantages oflaser and laser-arc hybrid welding technology. High power fiber laser is becoming moreand more attractive in recent years due to its excellent characteristics, but the relatedresearch was far less than CO2laser and YAG laser because of it appearing in a relativelyshort time. Considering the domestic and foreign research situation, although the appliedscope of laser and laser-arc hybrid welding technology can be expanded with the help ofprocess investigation, it is greatly restricted in industrial practical applications on accountof the lack of understanding mechanisms.
In this dissertation, systematic process tests of fiber laser welding and its hybridwelding in aluminum alloy were carried out using the self-built test platform. Plasmabehaviors were observed by high-speed video and spectrometer, and the mechanisms werestudied, such as the influence of plasma on the laser energy transmission, the interactionbetween laser induced plasma/vapor and arc plasma, and so on. Aiming at practicalapplications, the formation mechanism and preventive measures of the weld defectsoccurring in fiber laser lap welding of aluminum alloy also were also studied. Thefollowing are the main results:
The plasma/vapor induced during fiber laser welding of aluminum alloy can be roughlydivided into two parts: the keyhole plasma and the floating plasma. The keyhole plasma isfound close to the keyhole and always exists, but its size and brightness changeperiodically. As its size increases, its brightness also increases. The floating plasma staysabove the weld pool. Its size and brightness also change periodically, and it can be blownaway by the gas flow. The periodic change of the floating plasma synchronizes closelywith that of the keyhole plasma. The laser induced plasma/vapor oscillates periodically atcycles of450to600s. The use of a shielding gas has little effect on the oscillation cycle.A new interpretation about the periodical oscillation of plasma/vapor induced during fiberlaser welding was developed-the periodic oscillation of the plasma/vapor can be largely attributed to the oscillation of the keyhole opening and the molten pool.
With the increase in the laser power and the decrease in welding speed during fiber laserwelding of aluminum alloy, the size of plasma/vapor increase, and they have the sameeffects on the penetration depth. Under a certain condition, the size of plasma/vapor canreflect the penetration depth. Plasma/vapor has little influence on the laser transmission;the method had a noteless effect on the penetration depth by blowing the plasma/vaporthrough the side shielding gas.
It can be found in the process research on5754aluminum alloy of2mm thickness infiber laser lap welding: weld joints with good surface appearance can be obtained underthe appropriate process parameters using the flat nozzle with the extended form; thoughplasma/vapor having less effect on the laser transmission, spatters are formed because ofpart of the liquid metal flying out molten pool under the action of plasma/vapor, and thespatters increase with the increase of laser power density; only when welding speed wasvery low, hot cracks would be produced due to less tendency to produce hot cracks, andthe critical welding speed of appearing hot cracks decrease with the decrease of the laserpower; the weld joints with tiny grains and little burning loss of low boiling point alloyelement Mg have good tensile shear performance and have no obvious joint softened zone,micro-hardness of which is slightly lower than the base metal.
A new kind of cavity was proposed-bi-film cavity, many of this kind of cavity withirregular shape and large size have acute angle and contain black oxide material interiorly.The formation of this kind of cavity can be attributed to the refractory oxide film betweenthe upper and lower sheets in the lap welding. This kind of unique cavity forming due tothe particularity of the lap welding had a prodigious influence on mechanical properties,which can be effectively decreased by means of chemical cleaning or mechanicalprocessing methods to remove the oxide film, the mechanical properties of weld jointsincrease greatly.
A new hybrid plasma model was developed, by which the mechanism of the interactionbetween laser induced plasma/vapor and arc plasma has been expounded. The hybridplasma forms a channel between the welding wire and the keyhole during the fiberlaser-MIG hybrid welding process. The channel is composed of two parts: region A and region B. Region A is generated by the laser induced plasma/vapor, the most significantchange is that its size and brightness are enlarged. Region B comes from the core of theelectrical arc, the most significant change is that its direction is altered.
本文在自行构建的系统平台上，通过系统的铝合金光纤激光及其复合焊接工艺实验，采用高速摄像和光谱仪对等离子体行为进行观测，研究了等离子体对激光能量传输的影响、激光与电弧的相互作用等机理问题；并针对实际应用，对铝合金薄板的光纤激光搭接焊缺陷形成机理和预防措施进行研究。主要研究成果与创新工作如下：
光纤激光焊接铝合金时，等离子体/金属蒸气可以分为两个部分，一部分紧贴小孔，一直存在，但其亮度和体积呈现周期性变化；另一部分浮于熔池的上方，会被侧吹气体吹偏，有一个周期性的长大、脱离熔池并逐渐完全消散的过程。两部分的周期变化基本上是密切同步的，周期为450～600s，侧吹保护气体对等离子体/金属蒸气振荡周期无显著影响。提出了一种新的等离子体/金属蒸气周期振荡机理-小孔和熔池的周期性波动是造成等离子体/金属蒸气周期振荡的主要原因。
光纤激光焊接铝合金时，随着激光功率的增大、焊接速度的减小，等离子体/金属蒸气增大，与它们对焊缝熔深的影响一致，在一定条件下，等离子体/金属蒸气的大小可以反映焊缝熔深大小；等离子体/金属蒸气对激光传输影响不大，甚至可以说对光纤激光是透明的，通过侧吹保护气吹等离子体/金属蒸气的方法对熔深的影响不明显。
对2mm厚5754铝合金进行光纤激光搭接焊工艺研究，发现：采用扩张形扁平喷嘴在合适的工艺参数下，可以获得表面成形良好的焊缝；虽然等离子体/金属蒸气对激光传输影响不大，但是使得部分液态金属飞出熔池，形成飞溅，随着激光功率密度的增大，飞溅增多；产生热裂纹的倾向性较小，只有当焊接速度很低时，才会产生热裂纹，随着激光功率的减小，出现热裂纹的临界焊接速度降低；焊缝中低沸点合金元素Mg烧损很少，焊缝组织晶粒细小，显微硬度略低于母材，没有明显的接头软化，焊接接头具有良好的抗拉剪性能。
发现铝合金激光搭接焊时，会形成一种不同于冶金（氢）气孔和工艺气孔的特殊孔洞-夹层孔洞，尺寸较大、形状不规则，且多有锐角出现，往往内部含有黑色氧化物质。这是由于搭接焊时，上、下两层板之间夹层中存在难熔氧化膜引起的，这种因搭接焊的特殊性而形成的独特气孔对焊接接头力学性能影响很大，通过化学清洗或者机械加工方法清除氧化膜能够有效减少夹层气孔的产生，使焊接接头力学性能大大提高。
提出一种新的复合等离子体模型：在焊丝端部到小孔之间会形成一个复合等离子体通道，由A和B两部分组成：A部分来源于单激光等离子体/金属蒸气，但是在体积和亮度上都有很大增强；B部分来源于单MIG电弧，但是方向上发生了很大偏转。通过该模型阐释了激光光致等离子体/金属蒸气与电弧的相互作用机理。
It will be widely applied in the modern industrial fields due to prominent advantages oflaser and laser-arc hybrid welding technology. High power fiber laser is becoming moreand more attractive in recent years due to its excellent characteristics, but the relatedresearch was far less than CO2laser and YAG laser because of it appearing in a relativelyshort time. Considering the domestic and foreign research situation, although the appliedscope of laser and laser-arc hybrid welding technology can be expanded with the help ofprocess investigation, it is greatly restricted in industrial practical applications on accountof the lack of understanding mechanisms.
In this dissertation, systematic process tests of fiber laser welding and its hybridwelding in aluminum alloy were carried out using the self-built test platform. Plasmabehaviors were observed by high-speed video and spectrometer, and the mechanisms werestudied, such as the influence of plasma on the laser energy transmission, the interactionbetween laser induced plasma/vapor and arc plasma, and so on. Aiming at practicalapplications, the formation mechanism and preventive measures of the weld defectsoccurring in fiber laser lap welding of aluminum alloy also were also studied. Thefollowing are the main results:
The plasma/vapor induced during fiber laser welding of aluminum alloy can be roughlydivided into two parts: the keyhole plasma and the floating plasma. The keyhole plasma isfound close to the keyhole and always exists, but its size and brightness changeperiodically. As its size increases, its brightness also increases. The floating plasma staysabove the weld pool. Its size and brightness also change periodically, and it can be blownaway by the gas flow. The periodic change of the floating plasma synchronizes closelywith that of the keyhole plasma. The laser induced plasma/vapor oscillates periodically atcycles of450to600s. The use of a shielding gas has little effect on the oscillation cycle.A new interpretation about the periodical oscillation of plasma/vapor induced during fiberlaser welding was developed-the periodic oscillation of the plasma/vapor can be largely attributed to the oscillation of the keyhole opening and the molten pool.
With the increase in the laser power and the decrease in welding speed during fiber laserwelding of aluminum alloy, the size of plasma/vapor increase, and they have the sameeffects on the penetration depth. Under a certain condition, the size of plasma/vapor canreflect the penetration depth. Plasma/vapor has little influence on the laser transmission;the method had a noteless effect on the penetration depth by blowing the plasma/vaporthrough the side shielding gas.
It can be found in the process research on5754aluminum alloy of2mm thickness infiber laser lap welding: weld joints with good surface appearance can be obtained underthe appropriate process parameters using the flat nozzle with the extended form; thoughplasma/vapor having less effect on the laser transmission, spatters are formed because ofpart of the liquid metal flying out molten pool under the action of plasma/vapor, and thespatters increase with the increase of laser power density; only when welding speed wasvery low, hot cracks would be produced due to less tendency to produce hot cracks, andthe critical welding speed of appearing hot cracks decrease with the decrease of the laserpower; the weld joints with tiny grains and little burning loss of low boiling point alloyelement Mg have good tensile shear performance and have no obvious joint softened zone,micro-hardness of which is slightly lower than the base metal.
A new kind of cavity was proposed-bi-film cavity, many of this kind of cavity withirregular shape and large size have acute angle and contain black oxide material interiorly.The formation of this kind of cavity can be attributed to the refractory oxide film betweenthe upper and lower sheets in the lap welding. This kind of unique cavity forming due tothe particularity of the lap welding had a prodigious influence on mechanical properties,which can be effectively decreased by means of chemical cleaning or mechanicalprocessing methods to remove the oxide film, the mechanical properties of weld jointsincrease greatly.
A new hybrid plasma model was developed, by which the mechanism of the interactionbetween laser induced plasma/vapor and arc plasma has been expounded. The hybridplasma forms a channel between the welding wire and the keyhole during the fiberlaser-MIG hybrid welding process. The channel is composed of two parts: region A and region B. Region A is generated by the laser induced plasma/vapor, the most significantchange is that its size and brightness are enlarged. Region B comes from the core of theelectrical arc, the most significant change is that its direction is altered.
引文
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