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Operando X-Ray Tomoscopy of Laser Beam Welding.

Paul Hans Kamm1,2, Stephan Börner3, Tillmann Robert Neu1,2

  • 1Institute of Applied Materials, Helmholtz-Zentrum Berlin für Materialien und Energie, Hahn-Meitner-Platz 1, 14109, Berlin, Germany.

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Advanced X-ray imaging reveals dynamic weld pool behavior, quantifying porosity evolution during laser welding. Dynamic beam modulation significantly reduces defects by enhancing pore mobility and degassing.

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Laser Processing

Background:

  • Understanding weld seam phenomena during laser beam advancement is crucial.
  • Porosity formation and melt blowouts in metallic components require detailed investigation.

Purpose of the Study:

  • To capture and analyze the temporal evolution of the melt pool during laser welding.
  • To quantify pore characteristics and their dynamic patterns with high time resolution.
  • To evaluate the impact of dynamic beam modulation on weld quality.

Main Methods:

  • Utilized a high-speed X-ray tomoscopy setup (100 3D images/second).
  • Investigated AlSi9Cu3(Fe) die-casting under laser beam irradiation.
  • Quantified pore number, size, shape, and distribution at 10 ms resolution.
  • Compared conventional laser welding with dynamic beam modulation.

Main Results:

  • Observed complex dynamic patterns in pore evolution.
  • Dynamic beam modulation led to reduced porosity and surface roughness.
  • Attributed improvements to increased pore mobility and stepwise degassing.
  • Visualized the 3D keyhole formation within the melt pool over 10 ms.

Conclusions:

  • High-speed X-ray tomoscopy provides unprecedented insight into laser welding dynamics.
  • Dynamic beam modulation is a promising technique for improving weld quality in AlSi9Cu3(Fe).
  • The study elucidates mechanisms behind defect reduction, offering pathways for process optimization.