Common problems and solutions in laser welding

Mon, 08 Jan 2024 00:59:07 GMT

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Laser welding is an advanced welding technology that utilizes high-energy laser pulses to melt materials and achieve material connections.
Nowadays, laser welding is widely used in many fields, such as mechanical manufacturing, automotive parts, electronic equipment, jewelry industry, and aerospace. In these fields, laser welding can solve problems that traditional welding methods are difficult to handle, such as high welding difficulty and high requirements for weld aesthetics.
However, laser welding also has some defects. Sometimes, processing errors may occur due to operational or parameter settings.

Ten Common Defects and Solutions

1. Splash
During the welding process, if the surface of the processed material or workpiece is not cleaned thoroughly, there may be oil stains or pollutants, which may also be caused by the evaporation of the galvanized layer.
Solution: Pay attention to cleaning materials or workpieces and reduce welding energy appropriately.

2. Cracks
Mainly thermal cracks, such as crystallization cracks, liquefaction cracks, etc., are caused by the significant shrinkage force generated by the weld seam before complete solidification.
Solution: Measures such as wire filling and preheating can reduce or eliminate cracks.

3. Stomata
Laser welding has a deep and narrow molten pool, and a fast cooling speed. The gas generated in the liquid melt pool cannot overflow in time, which can easily lead to the formation of pores. The surface of the weld seam is not cleaned thoroughly, or the zinc vapor evaporates from the galvanized sheet.
Solution: Cleaning the surface of the workpiece before welding can reduce the tendency of porosity, and the direction of blowing can also affect the generation of porosity.

4. Biting edge
If the welding speed is too fast, the liquid metal pointing towards the center of the weld at the back of the small hole will not have time to redistribute, and solidification will form undercuts on both sides of the weld. Excessive gap in joint assembly reduces the melting of metal during joint filling and can also lead to undercutting.
Solution: Matching power and speed can effectively solve the problem of undercutting; Polish, clean, and repair the weld seam undercuts found during inspection.

5. Collapse
If the welding speed is slow, the molten pool is large and wide, the amount of molten metal increases, and the surface tension is difficult to maintain heavy liquid metal, the center of the weld will sink, forming collapse and pits.
Solution: It is necessary to reduce the energy density appropriately to avoid the collapse of the molten pool.

6. Poor fluidity of the melt pool
Poor fluidity of the molten pool can lead to problems such as uneven welding and poor weld formation.
Solution: Adjust parameters such as welding current, voltage, and welding speed to improve the fluidity of the molten pool.

7. Uneven weld seam
Uneven weld seam refers to phenomena such as poor width, depth, and forming of the weld seam.
Solution: Adjust parameters such as laser power, welding speed, and wire feeding speed, optimize welding process parameters, and improve the uniformity of the weld seam.

8. Inclusions and inclusions
Slag and inclusions refer to impurities remaining in the weld seam during the welding process.
Solution: Control parameters such as welding speed, laser power, and shielding gas flow to reduce the generation of slag and inclusions. Meanwhile, process measures such as vibration or stirring can be used to further optimize welding quality.

9. The weld seam is not aesthetically pleasing
The unattractive weld seam can affect the overall quality of the workpiece.
Solution: Adjust laser power and welding speed, optimize welding process parameters to improve the aesthetics of the weld seam.

10. Welding deviation
Inaccurate positioning during welding or inaccurate filling welding time and wire alignment can lead to welding deviations.
Solution: Adjust the welding position, or adjust the repair welding time and the position of the welding wire, as well as the position of the lamp, welding wire, and weld seam.

The above are the ten common defects and solutions in laser welding. If there are other problems during the welding process, you can contact General Electric for consultation.