激光—电弧相互作用及激光-TIG复合焊接新工艺研究
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摘要
激光-电弧复合焊接是将物理性质、能量传输机制截然不同的两种热源复合于一体的先进焊接技术。激光电弧复合焊接能够弥补单纯激光焊接的不足,极大地增强工艺适应性,改善焊缝成形,提高接头质量。近年来,该技术在发达国家受到了广泛关注并得到了积极的研究。激光与电弧的复合不是两种热源的简单相加,深入研究激光-电弧的相互作用机理对深刻理解复合焊接过程,优化焊接工艺具有重要意义。
复合焊接时,激光辐照母材的热效应及光致等离子体对激光-电弧相互作用产生重要影响;同时电弧吸收激光能量后,导致局部电子密度及电子密度梯度升高,引起吸收和折射效应的进一步增强。本文首先在不考虑这些因素的条件下,以激光在等离子体中的传播理论为基础,通过经典电子-离子碰撞理论,计算了电弧等离子体对入射激光的线性逆韧致吸收系数及折射率;在电子能量方程中引入逆韧致吸收项A(z),根据最小电压原理修正了激光作用电弧后的电弧电子能量方程。从理论上分析了激光作用电弧后,光束特性及电弧特性地变化趋势,揭示了激光-电弧相互作用时光束特性及电弧特性变化的物理机制及影响因素。
随后,采用3500W扩散冷却CO2激光器、4000W Yb:YAG盘片激光器、Fronius TS5000直流数字电源,借助高速摄像仪、瞬态光谱仪、光束光斑诊断仪及功率计,试验研究了高功率聚焦激光束与TIG电弧相互作用时的光束特性和电弧特性的变化规律。试验中为了避免激光作用母材时的热效应,同时直接测量激光穿过电弧后的光束参量及电弧对激光能量的吸收率,采用聚焦光束垂直穿过直流TIG电弧,焦点位于电弧轴线的布置方式;使用高速摄像仪拍摄了激光作用前后的电弧形态变化,瞬态光谱仪分别记录电弧不同部位的局部光谱,通过对电弧局部位置的光谱分析,采用波尔兹曼图法计算了电弧局部温度,并根据Saha方程计算了电弧等离子体局部电子浓度。着重分析了激光功率、电弧电流、激光作用位置对激光能量传输率、光斑直径、光束传输方向及电弧静特性、电弧形态、电弧功率、电弧轴线温度分布及电子数密度的影响规律;探讨了激光作用电弧后,光束特性及电弧特性发生变化的原因;研究了电弧气氛、激光波长对相互作用的影响规律及作用机制。
最后在激光-电弧相互作用研究的基础上,针对薄板搭接、对接、T型接头及厚壁对接开展了几种激光-TIG填丝复合焊接新工艺研究。为克服填丝复合焊接的飞溅和焊接烟尘对聚焦镜的污染,根据激光焊接时飞溅颗粒的运动状态和运动规律,基于气体动力学原理设计了超音速非对称拉伐尔腔体结构的横向气帘喷嘴;对比激光填丝焊接,研究了激光-TIG填丝复合焊接的工艺特性、焊缝成形、内部缺陷及工艺适应性;通过工艺参数优化,获得了理想的复合焊接薄壁T型接头及厚板对接接头;将激光电弧复合焊接技术与采用辅助电流的激光焊接方法有机结合,开发了强化电流磁流体动力学效应的激光电弧复合焊接方法。
Laser-arc hybrid welding is an advanced welding technology by combining two heat sources with different physical characteristics and energy transfer mechanisms. Laser-arc hybrid welding can make up for the deficiencies of individual laser process and take great effects on increasing the joint fit-up tolerance, enhancing the process stability, eliminating the weld defects, and improving the welding efficiency. Therefore, the laser-arc hybrid welding is receiving intensive study all over the world in recent years. The hybrid of the laser and the arc is not just a simple combination, so the investigation and comprehension on the physical phenomena and mechanism of the interaction between the laser beam and the arc plasma are significant for understanding of the hybrid process essentially.
In laser-arc hybrid welding process, the thermal effect and the laser-induced plasma which generated during laser radiation on metal have significant influences on laser-arc interaction. At the same time, the local electron density and the grads of electron density increase with more laser energy absorbed by arc, which induces more absorption and the refraction. In this thesis, the theory of laser propagation in arc plasma is described and the inverse bremsstrahlung absorption coefficient and the refractive index of arc for incident laser beam are calculated according to classic electron-ion collision theory without taking the thermal effect and the laser-induced plasma into consideration. At the same time, the electron energy equation of arc is amended by introducing A(z) of inverse bremsstrahlung absorption term. The variation trends of the characteristics of beam and arc in laser-arc interaction are analyzed in theoretical, and the physical mechanism and the influence factors are investigated.
Then, the characteristics of laser and arc during the interaction between high power laser and DC TIG arc are investigated in many aspects. The heat sources used in the experiment are Rofin DC035 Slab CO2 laser, DS 040 HQ DISC Yb:YAG laser and Fronius TS5000 digital arc welding system. The measurement instruments are Molectron 3sigma laser power meter, Prometec UFF100 beam diagnosis, PHOTRON Fastcam 1024R2 fast camera and Research Spectra Pro 2500i spectrometer. In order to eliminate the influence of the laser-induced thermal effect and directly measure the laser beam parameters and the laser power absorbed by the arc, the laser beam and the TIG arc are vertically set up in the experiment, with the focal spots set at the central axis of the TIG arc. During the experiment, the arc configuration is taken with the high speed camera, the spectrum of the arc plasma is acquired by the spectrograph, the local arc temperature is calculated by Boltzmann plot and the electron density of arc plasma is computed by the Saha equation. The effects of laser power, arc current and laser incident position on the characteristics of beam and arc plasma, such as laser power transmit ratio, beam diameter, laser propagating direction, voltage-current characteristic, arc configuration, arc power, arc temperature and electron density, are investigated in detail and the interaction mechanisms are analyzed. Furthermore, the influences of arc atmosphere and laser wavelength on the laser-arc interaction are analyzed, and the causes for the different interaction phenomena are investigated.
After the laser-arc interaction experimental investigations, some novel CO2 laser-TIG arc hybrid welding processes for thin walled butt joint, lap joint and T-joint and heavy section butt joint are exploited. In order to protect the optics lens from the welding spatter and smoke in laser-arc hybrid welding process, an aerodynamic theory-based ultrasonic cross-jet with a non-symmetric Laval cavity is designed according to the moving status and the pattern of spatter particles. Compared with laser welding with filler wire, the characteristics of laser-TIG hybrid welding with filler wire are investigated, which include appearance of the welds, the decrease of defects and the tolerance in gap and unfitness. By optimizing the process parameters, sound thin walled T-joint and heavy section butt joint can be obtained by CO2 laser-TIG hybrid welding process. The laser-arc hybrid welding process with magnetohydrodynamics reinforcing is developed with an integration of laser-arc hybrid welding and laser welding with external electrical current.
复合焊接时,激光辐照母材的热效应及光致等离子体对激光-电弧相互作用产生重要影响;同时电弧吸收激光能量后,导致局部电子密度及电子密度梯度升高,引起吸收和折射效应的进一步增强。本文首先在不考虑这些因素的条件下,以激光在等离子体中的传播理论为基础,通过经典电子-离子碰撞理论,计算了电弧等离子体对入射激光的线性逆韧致吸收系数及折射率;在电子能量方程中引入逆韧致吸收项A(z),根据最小电压原理修正了激光作用电弧后的电弧电子能量方程。从理论上分析了激光作用电弧后,光束特性及电弧特性地变化趋势,揭示了激光-电弧相互作用时光束特性及电弧特性变化的物理机制及影响因素。
随后,采用3500W扩散冷却CO2激光器、4000W Yb:YAG盘片激光器、Fronius TS5000直流数字电源,借助高速摄像仪、瞬态光谱仪、光束光斑诊断仪及功率计,试验研究了高功率聚焦激光束与TIG电弧相互作用时的光束特性和电弧特性的变化规律。试验中为了避免激光作用母材时的热效应,同时直接测量激光穿过电弧后的光束参量及电弧对激光能量的吸收率,采用聚焦光束垂直穿过直流TIG电弧,焦点位于电弧轴线的布置方式;使用高速摄像仪拍摄了激光作用前后的电弧形态变化,瞬态光谱仪分别记录电弧不同部位的局部光谱,通过对电弧局部位置的光谱分析,采用波尔兹曼图法计算了电弧局部温度,并根据Saha方程计算了电弧等离子体局部电子浓度。着重分析了激光功率、电弧电流、激光作用位置对激光能量传输率、光斑直径、光束传输方向及电弧静特性、电弧形态、电弧功率、电弧轴线温度分布及电子数密度的影响规律;探讨了激光作用电弧后,光束特性及电弧特性发生变化的原因;研究了电弧气氛、激光波长对相互作用的影响规律及作用机制。
最后在激光-电弧相互作用研究的基础上,针对薄板搭接、对接、T型接头及厚壁对接开展了几种激光-TIG填丝复合焊接新工艺研究。为克服填丝复合焊接的飞溅和焊接烟尘对聚焦镜的污染,根据激光焊接时飞溅颗粒的运动状态和运动规律,基于气体动力学原理设计了超音速非对称拉伐尔腔体结构的横向气帘喷嘴;对比激光填丝焊接,研究了激光-TIG填丝复合焊接的工艺特性、焊缝成形、内部缺陷及工艺适应性;通过工艺参数优化,获得了理想的复合焊接薄壁T型接头及厚板对接接头;将激光电弧复合焊接技术与采用辅助电流的激光焊接方法有机结合,开发了强化电流磁流体动力学效应的激光电弧复合焊接方法。
Laser-arc hybrid welding is an advanced welding technology by combining two heat sources with different physical characteristics and energy transfer mechanisms. Laser-arc hybrid welding can make up for the deficiencies of individual laser process and take great effects on increasing the joint fit-up tolerance, enhancing the process stability, eliminating the weld defects, and improving the welding efficiency. Therefore, the laser-arc hybrid welding is receiving intensive study all over the world in recent years. The hybrid of the laser and the arc is not just a simple combination, so the investigation and comprehension on the physical phenomena and mechanism of the interaction between the laser beam and the arc plasma are significant for understanding of the hybrid process essentially.
In laser-arc hybrid welding process, the thermal effect and the laser-induced plasma which generated during laser radiation on metal have significant influences on laser-arc interaction. At the same time, the local electron density and the grads of electron density increase with more laser energy absorbed by arc, which induces more absorption and the refraction. In this thesis, the theory of laser propagation in arc plasma is described and the inverse bremsstrahlung absorption coefficient and the refractive index of arc for incident laser beam are calculated according to classic electron-ion collision theory without taking the thermal effect and the laser-induced plasma into consideration. At the same time, the electron energy equation of arc is amended by introducing A(z) of inverse bremsstrahlung absorption term. The variation trends of the characteristics of beam and arc in laser-arc interaction are analyzed in theoretical, and the physical mechanism and the influence factors are investigated.
Then, the characteristics of laser and arc during the interaction between high power laser and DC TIG arc are investigated in many aspects. The heat sources used in the experiment are Rofin DC035 Slab CO2 laser, DS 040 HQ DISC Yb:YAG laser and Fronius TS5000 digital arc welding system. The measurement instruments are Molectron 3sigma laser power meter, Prometec UFF100 beam diagnosis, PHOTRON Fastcam 1024R2 fast camera and Research Spectra Pro 2500i spectrometer. In order to eliminate the influence of the laser-induced thermal effect and directly measure the laser beam parameters and the laser power absorbed by the arc, the laser beam and the TIG arc are vertically set up in the experiment, with the focal spots set at the central axis of the TIG arc. During the experiment, the arc configuration is taken with the high speed camera, the spectrum of the arc plasma is acquired by the spectrograph, the local arc temperature is calculated by Boltzmann plot and the electron density of arc plasma is computed by the Saha equation. The effects of laser power, arc current and laser incident position on the characteristics of beam and arc plasma, such as laser power transmit ratio, beam diameter, laser propagating direction, voltage-current characteristic, arc configuration, arc power, arc temperature and electron density, are investigated in detail and the interaction mechanisms are analyzed. Furthermore, the influences of arc atmosphere and laser wavelength on the laser-arc interaction are analyzed, and the causes for the different interaction phenomena are investigated.
After the laser-arc interaction experimental investigations, some novel CO2 laser-TIG arc hybrid welding processes for thin walled butt joint, lap joint and T-joint and heavy section butt joint are exploited. In order to protect the optics lens from the welding spatter and smoke in laser-arc hybrid welding process, an aerodynamic theory-based ultrasonic cross-jet with a non-symmetric Laval cavity is designed according to the moving status and the pattern of spatter particles. Compared with laser welding with filler wire, the characteristics of laser-TIG hybrid welding with filler wire are investigated, which include appearance of the welds, the decrease of defects and the tolerance in gap and unfitness. By optimizing the process parameters, sound thin walled T-joint and heavy section butt joint can be obtained by CO2 laser-TIG hybrid welding process. The laser-arc hybrid welding process with magnetohydrodynamics reinforcing is developed with an integration of laser-arc hybrid welding and laser welding with external electrical current.
引文
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