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Hybrid Laser Arc Welding PDF

328 Pages·2009·6.85 MB·English
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Hybrid laser–arc welding Related titles: MIG welding guide (ISBN 978-1-85573-947 5) Gas metal arc welding (GMAW) also referred to as MIG (metal inert gas) is one of the key processes in industrial manufacturing. MIG welding guide provides com- prehensive, easy-to-understand coverage of this widely used process. The reader is presented with a variety of topics from the choice of shielding gases, fi ller materials, welding equipment and lots of practical advice. The book provides an overview of new developments in various processes such as: fl ux cored arc welding; new high productive methods; pulsed MIG welding; MIG-brazing; robotic welding ap plications and occupational health and safety. This is essential reading for welding engineers, production engineers, designers and all those involved in industrial manufacturing. Advanced welding processes (ISBN 978-1-84569-130-1) This book introduces the range of advanced welding techniques currently in use. It covers gas tungsten arc welding (GTAW), gas metal arc welding (GMAW), high energy density processes such as laser welding, and narrow gap welding methods. The book reviews general issues such as power sources, fi ller materials and shielding gases. Particular attention is given to monitoring and process control as well as to automation and robotics. Computational welding mechanics (ISBN 978-1-84569-221-6) This book begins by discussing the physics of welding before going on to review modelling methods and options as well as validation techniques. It also reviews applications in areas such as fatigue, buckling and deformation, improved service life of components and process optimisation. Some of the numerical methods described in the book are illustrated using software available from the author which allows readers to explore CWM in more depth. Details of these and other Woodhead Publishing materials books can be obtained by: • visiting our web site at www.woodheadpublishing.com • contacting Customer Services (e-mail: [email protected]; fax: +44 (0) 1223 893694; tel.: +44 (0) 1223 891358 ext. 130; address: Woodhead Publishing Limited, Abington Hall, Granta Park, Great Abington, Cambridge CB21 6AH, UK) If you would like to receive information on forthcoming titles, please send your address details to: Francis Dodds (address, tel. and fax as above; e-mail: francis. [email protected]). Please confi rm which subject areas you are interested in. Hybrid laser–arc welding Edited by Flemming Ove Olsen Oxford Cambridge New Delhi Published by Woodhead Publishing Limited, Abington Hall, Granta Park, Great Abington, Cambridge CB21 6AH, UK www.woodheadpublishing.com Woodhead Publishing India Private Limited, G-2, Vardaan House, 7/28 Ansari Road, Daryaganj, New Delhi – 110002, India Published in North America by CRC Press LLC, 6000 Broken Sound Parkway, NW, Suite 300, Boca Raton, FL 33487, USA First published 2009, Woodhead Publishing Limited and CRC Press LLC © 2009, Woodhead Publishing Limited The authors have asserted their moral rights. This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. Reasonable efforts have been made to publish reliable data and information, but the authors and the publishers cannot assume responsibility for the validity of all materials. Neither the authors nor the publishers, nor anyone else associated with this publication, shall be liable for any loss, damage or liability directly or indirectly caused or alleged to be caused by this book. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfi lming and recording, or by any information storage or retrieval system, without permission in writing from Woodhead Publishing Limited. The consent of Woodhead Publishing Limited does not extend to copying for general distribution, for promotion, for creating new works, or for resale. Specifi c permission must be obtained in writing from Woodhead Publishing Limited for such copying. Trademark notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identifi cation and explanation, without intent to infringe. British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library. Library of Congress Cataloging in Publication Data A catalog record for this book is available from the Library of Congress. Woodhead Publishing ISBN 978-1-84569-370-1 (book) Woodhead Publishing ISBN 978-1-84569-652-8 (e-book) CRC Press ISBN 978-1-4398-0214-4 CRC Press order number: N10051 The publishers’ policy is to use permanent paper from mills that operate a sustainable forestry policy, and which has been manufactured from pulp which is processed using acid-free and elemental chlorine-free practices. Furthermore, the publishers ensure that the text paper and cover board used have met acceptable environmental accreditation standards. Typeset by SNP Best-set Typesetter Limited, Hong Kong Printed by TJ International Limited, Padstow, Cornwall, UK Contents Contributor contact details ix Preface xi Part I Characteristics of hybrid laser–arc welding 1 1 Advantages and disadvantages of arc and laser welding 3 E. W. Reutzel, Pennsylvania State University, USA 1.1 Introduction 3 1.2 Arc welding 3 1.3 Laser welding 15 1.4 Acknowledgments 25 1.5 References 25 2 Fundamentals of hybrid laser–arc welding 28 S. Katayama, Osaka University, Japan 2.1 Introduction 28 2.2 Plasma characteristics including interaction between laser beam and arc 29 2.3 Dynamic behavior 34 2.4 Melt dynamics and melt pool stability 37 2.5 Formation and prevention mechanism of porosity 41 2.6 References 44 3 Heat sources of hybrid laser–arc welding processes 47 A. Mahrle and E. Beyer, Dresden University of Technology, Germany 3.1 Introduction 47 v vi Contents 3.2 Laser beam heat sources 48 3.3 Arc heat sources 59 3.4 Combinations of laser beams and arcs 68 3.5 Future trends 77 3.6 References 78 4 Effect of shielding gas on hybrid laser–arc welding 85 M. Gao and X. Y. Zeng, Huazhong University of Science and Technology, China 4.1 Introduction 85 4.2 Common types and physical properties of shielding gases 86 4.3 Effects of shielding gas in hybrid welding 92 4.4 Effects of shielding gas on mechanical properties of the hybrid weld 100 4.5 Conclusions and sources of further information and advice 103 4.6 References 103 5 Properties of joints produced by hybrid laser–arc welding 106 V. Kujanpää, Lappeenranta University of Technology, Finland 5.1 Introduction 106 5.2 Microstructure of hybrid laser–arc welds 106 5.3 Hardness 112 5.4 Strength 116 5.5 Toughness 118 5.6 Fatigue properties 120 5.7 Corrosion properties 123 5.8 References 124 6 Quality control and assessing weld quality in hybrid laser–arc welding 127 J. K. Kristensen, FORCE Technology, Denmark 6.1 Introduction 127 6.2 Weldability of typical structural materials 127 6.3 Weld quality 134 6.4 Assessment of weld properties 136 6.5 Conclusions 138 6.6 Acknowledgements 139 6.7 References 139 Contents vii Part II Applications of hybrid laser–arc welding 141 7 Hybrid welding of magnesium alloys 143 L. Liu, Dalian University of Technology, China 7.1 Introduction 143 7.2 Weldability of magnesium alloys 144 7.3 Low-power laser–arc hybrid welding process 145 7.4 Numerical simulation 162 7.5 Infrared temperature measurement 167 7.6 Spectral diagnosis 168 7.7 Interaction between laser beam and arc plasma 172 7.8 Practical application 173 7.9 Conclusions and future trends 175 7.10 References 175 8 Shipbuilding applications of hybrid laser–arc welding 178 J. K. Kristensen, FORCE Technology, Denmark 8.1 Introduction 178 8.2 The approval of laser-based welding in shipbuilding 179 8.3 Industrial examples 184 8.4 Conclusions 190 8.5 References 191 9 Industrial robotic application of laser-hybrid and laser-hybrid-tandem welding 192 H. Staufer, Fronius International GmbH, Austria 9.1 Introduction 192 9.2 Laser-hybrid process for industrial applications 193 9.3 Applications and case studies in the automotive industry 195 9.4 Applications in shipbuilding 199 9.5 Synergies by LaserHybrid 204 9.6 The laser-hybrid-tandem welding process in the automotive industry 205 9.7 Application of LaserTandem welding in the pipeline industry 207 9.8 LaserTandem welding system 209 9.9 Laser-hybrid welding with three arcs: principles of laser-hybrid and laser-hybrid-tandem welding 211 9.10 Conclusions 214 9.11 References 215 viii Contents 10 Hybrid laser–arc welding of aluminium 216 C. Thomy, BIAS – Bremer Institut für angewandte Strahltechnik GmbH, Germany 10.1 Introduction 216 10.2 Aluminium and its alloys 217 10.3 Fusion welding of aluminium alloys 219 10.4 Hybrid laser–arc welding processes for aluminium alloys 228 10.5 Properties of hybrid laser–arc welds 245 10.6 Applications 258 10.7 Future trends 261 10.8 References 262 11 Hybrid laser–arc welding of dissimilar metals 270 C. Thomy, BIAS – Bremer Institut für angewandte Strahltechnik GmbH, Germany 11.1 Introduction 270 11.2 Specifi c aspects of and state-of-the-art in joining of dissimilar metals 271 11.3 Basic features of laser MIG hybrid welding for dissimilar metals 277 11.4 Process and joint properties 278 11.5 Application potentials 288 11.6 Future trends 291 11.7 References 291 Part III Hybrid laser–arc welding of steel 297 12 Hybrid laser–arc welding of steel 299 S. Katayama, Osaka University, Japan 12.1 Introduction 299 12.2 Hybrid laser–arc welding of steel and high tensile strength steel 300 12.3 Hybrid laser–arc welding of Zn-coated steel 307 12.4 Hybrid laser–arc welding of stainless steel 309 12.5 References 309 Index 312 Contributor contact details (* = main contact) Editor Chapter 3 Professor Flemming Ove Olsen Dr Achim Mahrle* IPU Dresden University of Technology, Produktionstorvet Institute of Surface and Bygning 425 Manufacturing Technology, DK-2800 Kgs. Lyngby Postbox, 01062 Dresden Denmark Germany Email: [email protected] Email: achim.mahrle@iws. fraunhofer.de Chapter 1 Professor Eckhard Beyer Dr E. W. Reutzel Dresden University of Technology, The Applied Research Laboratory Institute of Surface and The Pennsylvania State University Manufacturing Technology, P.O. Box 30 Postbox, 01062 Dresden, and State College Fraunhofer IWS, PA 16804-0030 Winterbergstraße 28, 01277 Dresden USA Germany Email: [email protected] Chapters 2 and 12 Professor S. Katayama Joining and Welding Research Institute (JWRI) Osaka University 11-1 Mihogaoka Ibaraki Osaka 567-0047 Japan E-mail: [email protected]. ac.jp ix

Description:
Hybrid laser-arc welding (HLAW) is a combination of laser welding with arc welding that overcomes many of the shortfalls of both processes. This important book gives a comprehensive account of hybrid laser-arc welding technology and applications. The first part of the book reviews the characteristic
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