Handbook of laser welding technologies

677 Pages·2013·38.86 MB·English

by  Seiji Katayama

Handbook of laser welding technologies
© Woodhead Publishing Limited, 2013
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© Woodhead Publishing Limited, 2013
Woodhead Publishing Series in Electronic and Optical Materials:
Number 41
Handbook of
laser welding
technologies
Edited by
Seiji Katayama
Oxford Cambridge Philadelphia New Delhi
© Woodhead Publishing Limited, 2013
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© Woodhead Publishing Limited, 2013
Contents
Contributor contact details xiii
Woodhead Publishing Series in Electronic and Optical Materials xvii
Preface xxi
Part I Developments in established laser welding
technologies 1
1 Introduction: fundamentals of laser welding 3
S. KATAYAMA, JWRI, Osaka University, Japan
1.1 Characteristics of laser welding 3
1.2 Lasers for welding 4
1.3 Laser welding phenomena 7
1.4 Laser weld penetration and welding defects 11
1.5 Evolution of laser welding 13
1.6 References 16
2 Developments in CO laser welding 17
2
S. TSUKAMOTO, National Institute for Materials Science, Japan
2.1 Introduction 17
2.2 Laser principles and types of lasers 17
2.3 Characteristics of CO laser beams 19
2
2.4 Laser–materials interactions 22
2.5 Welding phenomena and formation of defects 31
2.6 Industrial applications of CO laser welding 39
2
2.7 Future trends 44
2.8 Acknowledgements 44
2.9 References 44
3 Developments in Nd:YAG laser welding 47
R. FABBRO, Laboratoire PIMM (Arts et Métiers ParisTech – CNRS),
France
3.1 Introduction 47
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vi Contents
3.2 Basics of laser welding in keyhole (KH) mode with
solid-state lasers 48
3.3 Examples of weld speed variation on global behaviour of
keyhole (KH) and melt pool 61
3.4 Conclusion and future trends 67
3.5 References 69
3.6 Appendix: list of symbols 72
4 Developments in disk laser welding 73
K. LÖFFLER, TRUMPF Laser and Systems GmbH, Germany
4.1 Introduction: key principles of disk lasers 73
4.2 Technological trends and developments 77
4.3 Applications 78
4.4 Future trends 100
4.5 Sources of further information and advice 101
5 Developments in pulsed and continuous wave laser
welding technologies 103
J. ZHOU, Pennsylvania State University, USA and H. L. TSAI,
Missouri University of Science and Technology, USA
5.1 Introduction 103
5.2 Fundamentals of laser welding 104
5.3 New developments in laser welding 119
5.4 Future trends 131
5.5 References 132
6 Conduction laser welding 139
L. QUINTINO, Instituto Superior Técnico, Portugal, and E. ASSUNÇÃO,
European Federation for Welding, Joining and Cutting, Portugal
6.1 Introduction: comparison between keyhole and conduction
laser welding 139
6.2 The transition between conduction and keyhole mode 142
6.3 Conduction laser welding 147
6.4 Applications of conduction laser welding 151
6.5 References 157
7 Developments in laser microwelding technology 163
M. NAEEM, JK Laser, GSI Group, UK
7.1 Introduction 163
7.2 Laser choices for microwelding 165
7.3 Laser microwelding process 181
7.4 Defects and evaluation of microweld joints 194
7.5 Applications of laser microwelding 202
© Woodhead Publishing Limited, 2013
Contents vii
7.6 Conclusion and future trends 208
7.7 References 209
Part II Laser welding technologies for various materials 213
8 Laser welding of light metal alloys: aluminium and
titanium alloys 215
J. M. SÁNCHEZ AMAYA, Titania, Ensayos Y Proyectos Industriales
S.L., Spain, M. R. AMAYA-VÁZQUEZ and F. J. BOTANA, University of
Cadiz, Spain
8.1 Introduction to laser welding of aluminium alloys 215
8.2 Laser welding technologies for aluminium alloys 218
8.3 Microstructure, defects, mechanical properties and
corrosion behaviour of aluminium welds 226
8.4 Introduction to laser welding of titanium alloys 231
8.5 Laser welding technologies for titanium alloys 233
8.6 Microstructure, defects, mechanical properties and
corrosion behaviour of titanium welds 238
8.7 References and further reading 247
9 Laser welding and brazing of dissimilar metals 255
F. MÖLLER and C. THOMY, BIAS – Bremer Institut für
angewandte Strahltechnik GmbH, Germany
9.1 Introduction 255
9.2 Special issues in joining of dissimilar materials 256
9.3 Laser joining processes and their applications 259
9.4 Formation and properties of dissimilar joints 268
9.5 Future trends 275
9.6 References 276
10 Laser welding of plastics 280
I. JONES, TWI Ltd, UK
10.1 Introduction 280
10.2 History 280
10.3 Theory of welding plastics 281
10.4 Effect of main welding parameters 285
10.5 Modelling of plastics welding 285
10.6 Introduction to plastics welding processes 286
10.7 Polymer combinations that can be welded 289
10.8 Laser welding of plastics: process description 289
10.9 Welding parameters 297
10.10 Advantages and disadvantages of transmission laser
welding 298
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viii Contents
10.11 Applications 299
10.12 References 299
11 Laser welding of glass 301
I. MIYAMOTO, JWRI, Osaka University, Japan
11.1 Introduction 301
11.2 Features of glass welding 302
11.3 Glass welding by continuous wave (CW) lasers 304
11.4 Glass welding by ultrashort pulse lasers (USPL) 315
11.5 Conclusion and future trends 327
11.6 References 328
12 Defect formation mechanisms and preventive
procedures in laser welding 332
S. KATAYAMA, JWRI, Osaka University, Japan
12.1 Introduction 332
12.2 Terminology, characteristics, causes and preventive
procedures of laser welding imperfections and defects 333
12.3 Formation mechanisms and preventive procedures of
porosity 351
12.4 Formation mechanisms and preventive procedures of hot
cracking: solidification cracking and liquation cracking 361
12.5 References 370
13 Residual stress and distortion in laser welding 374
H. MURAKAWA, JWRI, Osaka University, Japan
13.1 Introduction 374
13.2 Causes of residual stress and distortion 376
13.3 Mechanism of formation of longitudinal and transverse
shrinkage of welded joints 380
13.4 Influential factors on welding distortion and residual
stress 385
13.5 Distortion and residual stress produced by laser welding 391
13.6 References 397
Part III Developments in emerging laser welding
technologies 399
14 Applications of robotics in laser welding 401
M. DE GRAAF, Cargotec ACT/University of Twente, The Netherlands,
and R. AARTS, University of Twente, The Netherlands
14.1 Introduction: key issues in robotic laser welding 401
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Contents ix
14.2 Connection topology 403
14.3 Coordinate frames and transformations 404
14.4 Tool calibration 406
14.5 Seam teaching and tracking 414
14.6 Trajectory-based control 415
14.7 Conclusion 419
14.8 References 420
15 Developments in beam scanning (remote)
technologies and smart beam processing 422
A. WETZIG, Fraunhofer IWS Dresden, Germany
15.1 Introduction 422
15.2 Beam movement over the workpiece 424
15.3 Beam shaping 426
15.4 Future trends 429
15.5 References 432
16 Developments in twin-beam laser welding technology 434
Y. MIYASHITA, Nagaoka University of Technology, Japan
16.1 Introduction 434
16.2 Numerical study on molten metal flow behavior during
twin-beam irradiation 435
16.3 Apparatus and procedure of twin-beam laser technique 436
16.4 Application of twin-laser beam 437
16.5 Conclusion 456
16.6 References 457
17 Developments in multi-pass laser welding technology
with filler wire 459
X. ZHANG, Hitachi Research Laboratory, Hitachi Ltd, Japan
17.1 Introduction 459
17.2 Principle of multi-pass welding with filler wire 460
17.3 Developments in technology 461
17.4 Future trends: further improvement of welding efficiency 471
17.5 References 476
18 Developments in hybridisation and combined laser
beam welding technologies 478
D. PETRING, Fraunhofer Institute for Laser Technology (ILT),
Germany
18.1 Introduction 478
18.2 Laser and arc hybrid welding 480
© Woodhead Publishing Limited, 2013