Laser-Arc Hybrid Welding for Titanium Blow Hole Suppression
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Solution Overview
Problem
Current welding methods for titanium and titanium alloys face challenges in achieving high welding speed with a good bead shape while minimizing defects like blow holes, particularly in the range of plate thicknesses from 0.3 to 2.5 mm.
Innovation Solution
A laser/arc hybrid welding method where the laser beam is angled between 10° and vertically, and TIG arc welding follows laser welding, with a controlled interval and shielding gas, to prevent blow holes and enhance bead quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser welding is used to achieve high welding speed and deep penetration, then welding speed and productivity are improved, but key holes may form and fluctuate causing blow holes and welding defects
Solution Approach 1:
The patent combines laser welding and TIG welding into a hybrid welding system where the laser beam provides deep penetration and high speed welding, while the TIG arc stabilizes the welding pool and prevents key hole fluctuations. This merging of two welding methods allows simultaneous achievement of high productivity and reliable weld quality without blow holes
Solution Approach 2:
The TIG arc acts as an intermediary element between the laser beam and the welding pool. It stabilizes the key hole formation process and controls the welding pool behavior, preventing harmful fluctuations that would otherwise cause blow holes while maintaining the high penetration capability provided by the laser
2Manufacturing precision
If TIG arc welding is used to achieve good bead shape, then bead quality is improved, but welding speed is limited to not more than 9 m/min
Solution Approach 1:
The patent merges TIG welding's advantage of producing excellent bead shapes with laser welding's high speed capability. The TIG arc is used to form the bead with precise control over shape and quality, while the laser provides the high energy density needed for fast welding speeds, achieving both good bead shape and high productivity simultaneously
Solution Approach 2:
The patent applies partial TIG arc action combined with laser welding. Instead of using full TIG welding which limits speed, only a portion of the welding process uses TIG arc (primarily for bead formation and pool stabilization) while the majority relies on high-speed laser welding, thus achieving good bead shape without sacrificing overall welding speed
3Use of energy by moving object
If laser welding is used to reduce total heat input and narrow heat-affected zone, then energy efficiency is improved, but key hole instability may cause gas entrapment and blow holes
Solution Approach 1:
The TIG arc serves as an intermediary that stabilizes the laser-induced key hole process. It provides a stabilizing effect on the welding pool and key hole fluctuations, preventing gas entrapment and blow hole formation while maintaining the low heat input and narrow heat-affected zone characteristics of laser welding
Solution Approach 2:
The patent changes the physical parameters of the welding process by superimposing TIG arc on laser welding. This parameter change stabilizes the key hole dynamics and welding pool behavior, preventing the formation of blow holes while preserving the energy efficiency advantages of laser welding
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for a welding speed of up to 20 m/min with smooth and wide bead shapes, effectively suppressing blow holes and improving overall weld quality.
Implementation Method 1
laser beam is radiated being slanted to the welding moving direction
Implementation Method 2
laser enables deep penetration and high speed welding due to having high energy density as a heat source
Implementation Method 3
TIG arc welding is advantageous in the respect that a good bead shape can be formed
Data Source
Figure 1~2
Figure 3(a)~3(b)
Figure 4(a)~4(b)
AI summary
Disclosed are: a welding method capable of increasing the welding speed up to approximately 20m/min., yet capable of producing good bead configurations and preventing welding defects such as blowholes; and a method of producing a welded member using the welding method. Specifically disclosed is a laser/arc hybrid welding method for butt-welding flat plates of stainless steel, titanium, or titanium alloy, or butt-welding both ends of a strip-shaped plate of stainless steel, titanium, or titanium alloy which has been formed into a tubular shape, wherein in the butt welding, the laser beam irradiation and the arc discharge trace the same welding line in such a manner that laser welding is followed by TIG arc welding.