Laser materials processing with diode lasers

Laser materials processing is currently dominated by CO2, Nd-YAG and Excimer lasers. Continuous advances in semiconductor laser technology over the last decade have increased the average power output of the devices annualy by two fold, resulting in the commercial availability of the diode lasers today with delivery output powers in excess of 60W in CW mode and 5kW in qasi-CW mode. The advantages of compactness, high reliability, high efficiency and potential low cost, due to the mass production capability of the diode laser, will inextricably shape its future in the field of materials processing. This papers reports on work exploring the feasibility of a range of materials processing applications using a Diomed 60W diode laser, transmitted through a 600m diameter optical fibre and coupled to a 3 axis CNC workstation. The applications studied include; marking and engraving natural stones (marble and granite), marking ceramic tiles, glazing and sealing tile grouts, marking and cutting glass, marking wood, welding metal wire and transformation hardening of tool steels. The study shows that even at the present limited power level of diode laser, many materials processing applications can be accomplished with satisfactory results. Through the study an initial understanding of interaction of diode laser beam with various materials has been gained. Also, within the paper basic beam characteristics, the state of the art of high power diode laser technology and current materials processing applications are also reviewed

A Review of Welding in Space and Related Technologies

Deployment of welding and additive manufacturing (AM) technologies in the space environment has the potential to revolutionize how orbiting platforms are designed, manufactured, and assembled. These technologies offer the option for repair of sustained damage to habitat structures on space missions, as astronauts would be able to manufacture new parts (using welding-derived AM processes suitable for use in the external space environment) and weld cracks. An added benefit is that required repairs can be achieved more economically, as new parts need not be shipped from Earth. With further maturation of in-space welding capabilities, astronauts could operate under given standards and weld damaged structures rather than rely on cargo resupply. This Technical Memorandum (TM) begins by reviewing the available literature relevant to welding in space, focusing on solidification, heat and mass transfer, and fluid flows in microgravity. This survey considers research on the effects of welding in microgravity on a material system. The various in-space welding devices that have been previously designed and tested are examined to determine their capabilities and shortcomings, with a focus on the results of their individual welding experiments. Safety measures are discussed to protect the orbiting International Space Station (ISS) and crew during welding operations. Finally, the state of the art is examined by focusing on current approaches to AM and on-orbit welding that are being developed by several companies in conjunction with NASA

The effects of short pulse laser surface cleaning on porosity formation and reduction in laser welding of aluminium alloy for automotive component manufacture

Laser welding of aluminium alloys typically results in porosity in the fusion zones, leading to poor mechanical and corrosion performances. Mechanical and chemical cleaning of surfaces has been used previously to remove contaminants for weld joint preparations. However, these methods are slow, ineffective (e.g. due to hydrogen trapping) or lead to environmental hazards. This paper reports the effects of short pulsed laser surface cleaning on porosity formation and reduction in laser welding of AC-170PX (AA6014) aluminium sheets (coated with Ti/Zr and lubricated using a dry lubricant AlO70) with two types of joints: fillet edge and flange couch, using an AA4043 filler wire for automotive component assembly. The effect of laser cleaning on porosity reduction during laser welding using a filler wire has not been reported before. In this work, porosity and weld fusion zone geometry were examined prior to and after laser cleaning. The nanosecond pulsed Nd:YAG laser cleaning was found to reduce porosity significantly in the weld fusion zones. For the fillet edge welds, porosity was reduced to less than 0.5% compared with 10–80% without laser cleaning. For flange couch welds, porosity was reduced to 0.23–0.8% with laser cleaning from 0.7% to 4.3% without laser cleaning. This has been found to be due to the elimination of contaminations and oxide layers that contribute to the porosity formation. The laser cleaning is based on thermal ablation

Laser Beam Welding of Austenitic Stainless Steels – Similar Butt and Dissimilar Lap Joints

Because of its inherent corrosion resistance, austenitic stainless steels, known as 300 series, have become cost-effective, staple materials for long-term applications in many industrial sectors including gas, petroleum, petrochemicals, fertilizers, food processing, and pulp industries as well as power generating plants. They have found also widespread use for manufacturing of chemical installations including stationary pressure tanks and tanks for transport of liquid and compressed gases, pipelines of high diameter in water power plants, for manufacturing of ships for transport of chemicals and installations of drilling rigs, etc. Thick-section stainless steels are widely used in the components and structures for nuclear power plants

Dissimilar laser welding of a NiTi shape memory alloy to Ti2AlNb

Funding Information: Acknowledgments: This work was supported by National Natural Science Foundation of China (No. 51775091), Science and Technology Project of Sichuan Province (No. 2020ZDZX0015). J.P. Oliveira acknowledges Fundação para a Ciência e a Tecnologia (FCT—MCTES) for its financial support via the project UID/00667/2020 (UNIDEMI). Funding Information: Funding: This work was supported by National Natural Science Foundation of China (No. 51775091), Science and Technology Project of Sichuan Province (No. 2020ZDZX0015). J.P. Oliveira acknowledges Fundação para a Ciência e a Tecnologia (FCT—MCTES) for its financial support via the project UID/00667/2020 (UNIDEMI). Funding Information: This work was supported by National Natural Science Foundation of China (No. 51775091), Science and Technology Project of Sichuan Province (No. 2020ZDZX0015). J.P. Oliveira acknowledges Funda??o para a Ci?ncia e a Tecnologia (FCT?MCTES) for its financial support via the project UID/00667/2020 (UNIDEMI).NiTi-based shape memory alloys and the Ti2AlNb alloy have gained increasing importance in the aerospace field. The joining of these two materials can further increment the importance and usage of these relevant engineering materials and expand their potential applications. However, when joining NiTi-based shape memory alloys to Ti-based alloys, the formation of brittle Ti-rich intermetallic compounds often occurs, significantly limiting their functionality and use. Dissimilar joints between a NiTi shape memory alloy and Ti2AlNb alloy were obtained using a 0.1 mm thick Niobium (Nb) interlayer via laser welding. By process optimization, sound joints were obtained. The microstructure evolution was assessed by means of electron microscopy, whereas the mechanical strength of the joints was evaluated using lap shear tensile testing. The best performing joints were seen to fracture at maximum loads above 1230 N, thus allowing us to consider this dissimilar pair for structural applications.publishersversionpublishe

Local Shielding Gas Supply in Remote Laser Beam Welding

The use of shielding gases in laser beam welding is of particular interest for materials interacting with ambient oxygen, e.g., copper, titanium or high-alloy steels. These materials are often processed by remote laser beam welding where short welds (e.g., up to 40 mm seam length) are commonly used. Such setups prevent gas nozzles from being carried along on the optics due to the scanner application and a small area needs to be served locally with inert gas. The article provides systematic investigations into the interaction of laser beam processes and parameters of inert gas supply based on a modular flat jet nozzle. Based on the characterization of the developed nozzle by means of high-speed Schlieren imaging and constant temperature anemometry, investigations with heat conduction welding and deep penetration welding were performed. Bead-on-plate welds were carried out on stainless steel AISI 304 for this purpose using a disc laser and a remote welding system. Argon was used as shielding gas. The interaction between Reynolds number, geometrical parameters and welding/flow direction was considered. The findings were proved by transferring the results to a complex weld seam geometry (C-shape)

Feasibility of remotely manipulated welding in space. A step in the development of novel joining technologies

In order to establish permanent human presence in space technologies of constructing and repairing space stations and other space structures must be developed. Most construction jobs are performed on earth and the fabricated modules will then be delivered to space by the Space Shuttle. Only limited final assembly jobs, which are primarily mechanical fastening, will be performed on site in space. Such fabrication plans, however, limit the designs of these structures, because each module must fit inside the transport vehicle and must withstand launching stresses which are considerably high. Large-scale utilization of space necessitates more extensive construction work on site. Furthermore, continuous operations of space stations and other structures require maintenance and repairs of structural components as well as of tools and equipment on these space structures. Metal joining technologies, and especially high-quality welding, in space need developing

CASE STUDIES FROM DIFFERENT TYPES OF HEAT EXCHANGERS TO PLATE AND SHELL HEAT EXCHANGER: A REVIEW

A Plate and Shell Heat Exchanger (PSHE) is manufactured with round welded plates in its core. These plates are designed to withstand high pressures and temperatures. Failures in this kind of heat exchanger were registered in a short operating period. To obtain the failure modes present in this equipment and a theoretical framework concerning this field of study, a research methodology was proposed (Systematic Literature Review – SLR) and a theoretical survey was carried out focusing in the 316L stainless steel and titanium grade 1 for its use in the Brazilian offshore industry. Seeing that the whole PSHE structure is welded, it is necessary to account for the strain caused by severe expansion processes in heat exchanger joints. This regarding, the laser welding process was investigated because of its narrow melting zone. It is believed that it was possible to clarify which failure modes are related to corrosive processes or stress concentration highlighting the structural and mechanical characterization models employed. Considering that the research field is relatively new, it was feasible to establish a theoretical basis of solutions applicable to PSHE, such as the use of more recessive material, reduce the corrosiveness of the operating medium, and reduce external sources of tension. Also, new content was assembled to assess the future decision-making process, regarding the design or maintenance of welded plate exchangers

A Laser-Based Vision System for Weld Quality Inspection

Welding is a very complex process in which the final weld quality can be affected by many process parameters. In order to inspect the weld quality and detect the presence of various weld defects, different methods and systems are studied and developed. In this paper, a laser-based vision system is developed for non-destructive weld quality inspection. The vision sensor is designed based on the principle of laser triangulation. By processing the images acquired from the vision sensor, the geometrical features of the weld can be obtained. Through the visual analysis of the acquired 3D profiles of the weld, the presences as well as the positions and sizes of the weld defects can be accurately identified and therefore, the non-destructive weld quality inspection can be achieved