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Laser welding is an efficient and precise welding method that uses a high-energy-density laser beam as a heat source.
Laser welding can be realized by continuous or pulsed laser beam, and the technical principle of laser welding can be divided into heat conduction welding and laser deep penetration welding. When the power density is less than 104~105 W/cm², it is heat conduction welding. At this time, the penetration depth is shallow and the welding speed is slow; when the power density is greater than 105~107 W/cm², the metal surface is concave into “holes” under the action of heat, forming deep penetration welding, which has the characteristics of fast welding speed and large aspect ratio.
Laser welding is one of the important aspects of the application of laser material processing technology. In the 1970s, it was mainly used for welding thin-walled materials and low-speed welding, and the welding process belongs to the heat conduction type. The principle of heat conduction laser welding is: the surface of the workpiece is heated by laser radiation, the surface heat diffuses to the interior through heat conduction, and the workpiece is melted by controlling the laser parameters such as the width, energy, peak power and repetition frequency of the laser pulse to form a specific molten pool. Due to its unique advantages, laser welding has been successfully used in the precision welding of micro and small parts.
Gear welding and metallurgical sheet welding mainly involve laser deep penetration welding. Laser deep penetration welding generally uses continuous laser beams to complete the connection of materials, and its metallurgical physical process is very similar to electron beam welding, that is, the energy conversion mechanism is completed through a “key-hole” structure. When the laser power density reaches 10^6~10^7 W/cm^2, the power input is far greater than the rate of heat conduction, convection and radiation heat loss, and the surface of the material vaporizes and forms small holes. The small hole is like a black body, which absorbs almost all the energy of the incoming laser beam. The equilibrium temperature in the hole is about 2500°C. The heat is transferred from the outer wall of the high-temperature hole and melts the metal surrounding the hole. The flow of the liquid outside the hole wall and the surface tension of the wall layer maintain a dynamic equilibrium with the vapor pressure continuously generated in the hole. The laser beam carries a large amount of light energy into the small hole continuously, and the material outside the small hole is continuously flowing. As the beam moves forward, the small hole is always in a steady state of flow. After the small hole and the molten metal surrounding the wall of hole move forward with the leading beam, the molten metal fills the cavity left by the removal of the small hole and condenses to form a weld, completing the welding process. The entire process happens extremely fast, allowing the welding speed to easily reach several meters per minute.
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