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Laser and arc manufacturing processes: A review

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DOI: 10.1007/s12541-016-0119-4

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 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 17, No. 7, pp. 973-985 JULY 2016 / 973
DOI: 10.1007/s12541-016-0119-4 ISSN 2234-7593 (Print) / ISSN 2005-4602 (Online)

Laser and Arc Manufacturing Processes: A Review

Choon-Man Lee1,#, Wan-Sik Woo1, Jong-Tae Baek1, and Eun-Jung Kim1

1 School of Mechanical Engineering, Changwon National University, 20, Changwondaehak-ro, Uichang-gu, Changwon-si, Gyeongsangnam-do, 51140, South Korea
# Corresponding Author / E-mail: cmlee@changwon.ac.kr, TEL: +82-55-213-3622, FAX: +82-55-267-1160

KEYWORDS: Laser hear source, Arc heat source, Processes, Hybrid processes

Manufacturing can be defined as the transformation of raw materials into desired products by various processes, such as machining,
welding and coating. Today, laser and arc heat sources are largely used as the means for processing raw materials. The laser is one
of the most widely used non-contact thermal energy sources in various processes, and the development of laser processes and devices
for effective manufacturing is still ongoing. Arc heat sources are widely used in welding and coating processes. In particular, the types
of welding processes using arc heat sources are very different depending on the materials used and the purpose of welding. In this
paper, individual processes using laser and arc heat that have been reported over the past five years are reviewed, including
machining, welding, sintering and coating. Then, hybrid processes that use laser and arc heat sources together are also reviewed.
The final part of this review provides a summary and discusses future trends for individual and hybrid processes using laser and arc
heat sources.

Manuscript received: June 7, 2016 / Revised: June 15, 2016 / Accepted: June 16, 2016 (Invited paper)

1. Introduction sources are reviewed. In Chapter 4, other hybrid processes (combining

Today’s advanced manufacturing technologies are able to produce
high-quality products with greater efficiency and productivity than ever
before. At the same time, new material processing methods are
required to process the advanced materials being developed in various
industrial fields. For example, titanium alloy, nickel-based alloy and
ceramics are difficult to machine by conventional machining methods
because of their exceptional mechanical properties. To enhance the
machinability of such materials, many researchers have been engaged
in efforts to develop new processes, and to investigate combinations of
individual processes (hybrid processes). In particular, laser and arc heat
sources have been widely used in hybrid approaches to process
materials. The development of many novel alternative techniques in the
last 20 years would not have been possible without laser and arc heat
sources, and their development has led to significant improvements in
product quality and productivity. Even today, new and advanced
processes using laser and arc heat sources are being actively developed
1-11
and adopted in a diverse range of applications.
In this review, the various processes using laser and arc heat sources
have been divided into three chapters. In Chapter 2, individual processes
using laser heat sources and hybrid processes (combinations of laser
and other energy sources except arc heat) from the past five years are
reviewed. In Chapter 3, processes from the past five years using arc heat
laser and arc heat sources) are reviewed. The final chapter of this
review provides a summary and discusses future trends in individual
and hybrid processes using laser and arc heat sources.
2. Laser Manufacturing Processes
The term laser is an acronym for light amplification by stimulated
emission of radiation, and a laser beam is a form of electro-magnetic
12
radiation. Today lasers are widely used in manufacturing industries.
These various laser-based processes can be divided into several types,
including machining, sintering, forming, welding and coating.
2.1 Laser machining
Laser machining is an effective process which involves thermal
7,13
energy and non-contact type processing. In this method, the laser
irradiation is employed to melt and vaporize the materials. Various
types of lasers are selectively applied depending on the type of
material, and combinations of laser and other energy sources have been
14-17
actively studied for machining.
2.1.1 Laser ablation
Laser ablation is a process that involves focusing a laser beam on

© KSPE and Springer 2016

 974 / JULY 2016 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 17, No. 7
Fig. 1 Schematic diagram of laser ablation process
Fig. 2 Configuration of laser-assisted machining (a combination of
laser irradiation and grinding)
a workpiece to remove material from the heated zone, as shown in Fig.
1. It is a non-contact machining method and can perform highly accurate
micromachining.
18
Echlin et al. studied a femtosecond laser ablation process with a
combined device. A TriBeam system was developed by combining
19
ultrafast lasers with an electron microscopy device. Povarnitsyn et al.
studied micro and macroscopic modeling of the femtosecond laser
ablation of metal. Two complementary approaches were suggested to
simulate the femtosecond laser ablation of a bulk aluminum target. The
first method used single-fluid two-temperature hydrodynamics (HD).
The second method was a combination of classical molecular dynamics
(MD). Results of the simulations showed that the two methods were in
good agreement over the range of experimental conditions.
2.1.2 Laser-assisted machining
Laser-assisted machining (LAM) is a novel alternative method for
processing difficult-to-cut materials. In this approach the workpiece is
preheated by laser prior to machining, and then the heated region of the
14-16
workpiece is machined by a cutting tool.
20
Kizaki et al. studied the LAM of zirconia ceramics using a diamond
bur and sintered Y-TZP blocks, as shown in Fig. 2. The LAM efficiency
was confirmed by experiments, which also found that the required
grinding force and tool damage was reduced by the LAM process.
21
Balbaa et al. studied the residual stress produced by LAM using the
finite element model. In order to predict residual stress in the cutting
direction, the cutting process was modelled using SPH. Also, the
effectiveness of LAM and the accuracy of the predicted model were
22
confirmed through experiments. Venkatesan et al. proposed a statistical
Fig. 3 Schematic description of laser-assisted ECM (a combination of
laser and ECM)
method for parameter optimization in the LAM of Inconel alloy. The
parameters selected for optimization were irradiation angle, laser power,
and cutting parameters such as cutting speed and feed rate. The effects
of each parameter were analyzed by design of experiment (DOE). As a
result, the optimum values of the parameters were determined. Under
the optimum conditions, cutting force was decreased by about 34%. Lee
23-27
et al. studied the three-dimensional laser-assisted milling (LAMill)
process. Preheating and machining experiments were performed
depending on the shapes of various workpieces. They confirmed a
reduction in cutting force and the improvement of surface quality
compared to conventional machining.
2.1.3 Laser-assisted ECM/EDM
This process is a combination of a laser heat source and
electrochemical machining (ECM), or electro-discharge machining
(EDM), as shown in Fig. 3. ECM and EDM are methods for removing
28-36
material using electrical energy.
37
De Sliva et al. performed laser assisted jet electrochemical
machining (LAJECM) to analyze the thermal effects. This hybrid
process was proposed to improve both accuracy and productivity. The
thermal effects in LAJECM were investigated by temperature distribution
modelling and experimental analysis. The highest surface quality was
38
achieved by Hastelloy, Kasashima et al. who developed a laser and
electrochemical complex machining system. Three-dimensional
measurements of the workpiece position were performed to reduce
machining error using the laser. Based on the measurement results, an
automatic position error was achieved, and an arbitrary stent shape using
the bit-map data pattern could be created. Finally, the stent outside was
39
removed by the ECM. Rasheed studied the micro-holes produced by
micro EDM with laser machining. In the case of laser machining, the
material removal rate (MRR) was much higher compared to EDM.
However, the surface quality and accuracy of shape were not good
compared to EDM. Consequently, hybrid process (EDM-laser
machining) can improve the MRR with excellent surface quality.
2.1.4 Laser water-jet/layer machining
40
Tangwarodomnukun et al. studied the underwater laser ablation of
titanium alloy, as shown in Fig. 4. This ablation method has become an
alternative machining process. The experimental results showed that a
clean cut can be obtained with less thermal damage under the water
41
layer. Mullick et al. studied a water-jet assisted underwater laser
cutting process. The type of laser and material used were a high power
fiber laser, and AISI 304 stainless steel sheet of 1.5 mm thickness,
respectively. The influence of the heat convection of the water jet and
 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 17, No. 7
Fig. 4 Schematic diagram of underwater laser ablation process
Fig. 5 Configuration of selective laser sintering
the scattering of the laser beam on the energy efficiency of the cutting
process was confirmed through experiments. When cutting speed was
high, the energy efficiency was enhanced. Also, an energy balance
model based on various mechanisms was developed.
2.2 Laser sintering
The laser sintering process is a type of additive manufacturing
technology. Laser sintering produces geometrically complex components
using fused or sinter powdered thermoplastics. However, this process is
42-44
still restricted by low accuracy and long production times.
2.2.1 Selective laser sintering
Selective laser sintering (SLS) is a manufacturing technique that a
component is produced by fusing small particles with a laser beam. The
powdered material is selectively fused with the laser beam by scanning
cross-sections on the surface of a powder bed. After one layer is scanned,
the powder bed is lowered and a new powder bed is applied on top.
44
Fig. 5 shows a schematic diagram of SLS process.
45
Shahzad et al. studied the additive manufacturing of zirconia parts
by indirect SLS. A spherical polypropylene-zirconia composite powder
for SLS was produced by thermally induced phase separation (TIPS).
The optimum SLS parameters were determined to create components
JULY 2016 / 975
46
for post-SLS processing. Theodorakos et al. studied the potential of
three different lasers based on pulse duration: continuous wave, pulsed
nanosecond and picosecond. For longer duration pulses, the laser beam
profile and average power were considered in order to avoid suddenly
high temperatures. These predictions were confirmed by experiments,
and efficient sintering with no evidence of substrate degradation was
obtained.
2.2.2 Direct metal laser sintering
47
Ventola et al. studied direct metal laser sintering (DMLS) of rough
surfaces with enhanced heat transfer electronics cooling. The artificial
roughness produced by DMLS was investigated through experiments. A
developed sensor was used to measure experimental data. As a result,
the peak convective heat transfer of rough flat surfaces was improved
by about 73% (63% on average) and the peak of finned surfaces was
48
improved by about 40% (35% on average). Yan et al. evaluated the
productivity and performance of aluminum alloy lattice structures
produced by DMLS. These structures could be manufactured by DMLS
because of the self-supporting nature of the diamond unit cell. The
geometric agreement between the original structure and the structure
produced by DMLS was excellent, but the strut sizes of the structure
fabricated by DMLS were higher than the original value. So, the
compressive modulus and strength of the structures, volume fraction
and unit size have a clear relationship.
2.3 Laser forming
49,50
Forming techniques include various plastic deformation processes.
The forming techniques can be classified into two types, bulk forming
and sheet forming. The concept of laser forming was first proposed by
51
Kitamura in Japan. Since then, interest in laser forming has increased
in various industries. Laser forming in sheet materials is typically free
from spring-back. Also, it has the general advantages of laser processing,
52-54
such as high speed and flexible manufacturing.
2.3.1 Laser solid forming
Laser solid forming (LSF) is an advanced manufacturing process for
metals. Complex parts can be directly fabricated with full density and
refined properties by LSF.
55
Liu et al. investigated the microstructural changes of an as-deposited
Inconel 718 workpiece in the deposition direction. The morphological
variations of dendrite growth were analyzed by the Kurz-Giovanola-
Trivedi (KGT) model. Reasonable arrangement was achieved in a
comparison of the values of the dendrite arm space produced by
56
experiments and the values obtained by KGT. Song et al. studied the
influence of forming atmosphere on the deposition characteristics of
2Cr13 stainless steel during LSF under an atmosphere of air, argon and
nitrogen. ANOVA analysis was used to confirm the effects of the
forming atmosphere on the deformation of the molten pool, effective
energy and mass during LSF. The deformation of the molten pool
decreased in the following order: under air > under nitrogen> under
argon.
2.3.2 Laser peen forming
Laser peen forming (LPF) is a sheet metals processing method
based on plastic deformation, used to form various shapes. Fig. 6 shows
 976 / JULY 2016
Fig. 6 Schematic description of laser peen forming
Fig. 7 Schematic diagram of laser welding
57
the principle of the laser peen forming process.
58
Sagisaka et al. studied LPF using a femtosecond laser. A pure
aluminum sheet was used and the forming properties were analyzed.
LPF experiments were performed according to various irradiation
conditions and density of pulses. As a result, this process was found to
59
be suitable for small quantity batch production. Hu et al. investigated
the effect of elastic prestress on the LPF of aluminum alloy 2024-T351.
The effect of elastic prestress on the deformed shape generated by LPF
was investigated by numerical modeling and experiments. Finally, LPF
was confirmed to have a small effect on the surface roughness, both
with and without prestress.
2.4 Laser welding
Laser welding is a welding technique employed to join components
by laser beam, as shown in Fig. 7. This process has some advantages,
60-62
including high welding speed, low thermal distortion and deep welds.
63
Gao et al. compared the properties of Ti-6Al-4V titanium alloy plate
welded using Nd:YAG laser welding and arc welding. The thickness of
the workpiece was 8 mm. During tensile tests, plastic strain was recorded
with a high speed camera. As a result, the joint welded by laser welding
exhibited characteristics such as small residual distortion, fine
64
microstructure and high strength compared to arc welding. Sun et al.
also compared laser welding and arc welding. A numerical simulation
and experiments were conducted to analyze the welding deformation
and the residual stress. As a result, the deformation by laser welding
65
was found to be significantly reduced. Chen et al. performed laser butt
welding of titanium alloy to stainless steel. The characteristics and
behavior of the joint welded by laser butt welding were investigated
according to laser offsetting. A scanning electron microscope was used
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 17, No. 7
Fig. 8 Configuration of laser cladding
to observe the microstructures of the joint. When the laser beam was
irradiated toward the stainless steel, a more durable joint was produced.
Also, when the laser beam was irradiated toward the stainless steel, the
tensile strength of the joint was higher than when it was directed
toward the titanium alloy.
2.5 Laser coating
Laser coating has some positive characteristics compared to arc
welding, including minimal distortion of the substrate, a narrow heat-
affected-zone (HAZ), better coating quality, with minimal dilution. The
purpose of laser coating is to enhance material properties by preparing
66
a protective layer with metallurgical bonding.
2.5.1 Laser cladding
12
Fig. 8 shows a schematic diagram of laser cladding. Rommel et
67
al. investigated diamond particles to produce a diamond tool using laser
cladding. The experiment was performed at nominal temperature using
a high power diode laser (HPDL). During laser cladding, temperature
measurement with laser power control was used. Finally, a metal bonded
68
diamond tool was produced by laser cladding. Yang et al. analyzed
the coating properties of titanium alloy using the laser direct cladding
method. As the laser scan speed increased, the surface roughness and
the crystallite size of the coatings decreased. Also, microhardness of the
69
alloy was changed according to laser scan speed. Li et al. investigated
the effect of Y O on the properties of TiB/TiC-reinforced composite
2 3
coatings using laser cladding. The wear mass loss was decreased due to
the high microhardness and fracture toughness of the coating with Y O . 2 3
Also, the wear resistance of the coating was improved by the addition
of Y O .
2 3
2.5.2 Laser-induction cladding
Recently, the laser-induction cladding process has been actively
70-72
studied by Wang et al. This research team studied various
characteristics of materials coated by laser-induction cladding and the
efficiency of the laser-induction cladding process. First, the
microstructures and mechanical properties of the composite coated by
laser-induction cladding were analyzed to confirm the effects of this
process. Second, the deposition rate and laser energy efficiency of the
 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 17, No. 7 JULY 2016 / 977

Fig. 9 Schematic diagram of laser-induction cladding Fig. 10 Schematic diagram of plasma arc cutting

Table 1 Types and characteristics of arc welding

Electrode type Electrode coating Filler rod Shielding gas Weld polarity
Shielded metal arc welding (SMAW) Consumable rod Yes Nil Nil AC/DCEP
Gas tungsten arc welding (GTAW) Non consumable Nil With/Without Yes DCEN/AC
Gas metal arc welding (GMAW) Consumable rod Nil Nil Yes DCEP
Submerged arc welding (SAW) Consumable rod Nil With/Without Nil AC/ DCEP
Plasma arc welding (PAW) Non consumable Yes Nil Yes DC

laser-induction cladding were investigated. The efficiency of the laser-

induction cladding was verified by comparing it with conventional laser
cladding. The maximum energy efficiency was about 64%. Fig. 9 shows
a schematic of the laser-induction cladding process (a combination of
laser and induction).

3. Arc Manufacturing Processes

An electric arc is a visible plasma discharge between two electrodes.
Arc processes using an arc heat source have advantageous features,
such as accurate control, low cost and increased productivity. For these
reasons, arc processes are used in various industrial fields.
3.1 Plasma arc cutting
Fig. 10 shows a schematic diagram of the plasma arc cutting (PAC)
process. PAC is known as a non-conventional manufacturing process
for the processing of various materials. The PAC process cuts metal by
melting a section of metal with a constricted arc. Manganese steel,
Fig. 11 Schematic description of shielded metal arc welding
75-84
various welding types.
3.2.1 Shielded metal arc welding
Fig. 11 shows a schematic diagram of the shielded metal arc welding
(SMAW) process. SMAW is evolved from carbon arc welding (CAW).
This process is used primarily to weld steels and iron.
75
Qin et al. studied the mass transfer of a nickel-based alloy covered
electrode with the near neutral CaO-CaF -TiO type flux coating during
2 2

stainless steel, titanium alloys, copper, magnesium, aluminum alloys SMAW. The highest mass transfer coefficients of Cr, Mn and Fe appear
76
and cast iron can all be processed by this method. in the basic CaO-CaF type covered electrodes. Buchely et al.
2

73
Deli et al. compared PAC operated by conventional PI control and
a PAC system based on a fuzzy-neural network. The experimental results
showed that high accuracy and finish of workpiece were obtained by the
74
PAC operated with the fuzzy controller. Chamarthi et al. investigated
the unevenness of a processed surface as a result of cutting parameters.
The parameters in the analysis and experiments included plate thickness,
arc voltage, cutting speed, and plasma gas flow rate. They determined that
improved surface quality could be obtained by varying the parameters
and optimum values were determined by experiments and analysis.
3.2 Arc welding
Table 1 summarizes the characteristics of arc welding according to
investigated the high-cycle fatigue strength and mechanical behavior of
stainless steel joints welded by the SMAW processes. The experimental
results showed that the final failure of a sample occurred in the welding
deposits. The growth and propagation of cracks were influenced by the
dendrite growth direction of the weld deposits.
3.2.2 Gas tungsten arc welding
Fig. 12 shows a schematic diagram of the gas tungsten arc welding
(GTAW) process. GTAW uses a non-consumable tungsten electrode and
a welding rod. This process was developed to perform the effective
welding of aluminum and magnesium alloys in the aircraft industry.
77
Qin et al. suggested a high speed tandem GTAW process for thin
 978 / JULY 2016
Fig. 12 Schematic diagram of gas tungsten arc welding
Fig. 13 Schematic diagram of gas metal arc welding
stainless steel. Assistant current was determined by analysis to be the
most influential parameter. In addition, as the assistant current increased,
the weld appearance quality was improved. However, increasing the
main current resulted in a decrease in the weld quality level. Nandagopal
78
et al. studied the mechanical properties and optimization of the GTAW
parameters of two dissimilar materials titanium and aluminum 7075. The
effect of parameters was analyzed by DOE. As a result, welding speed
was determined to be the most influential parameter for tensile strength.
3.2.3 Gas metal arc welding
Fig. 13 shows a schematic diagram of the gas metal arc welding
(GMAW) process. GMAW evolved from GTAW. Today, GMAW is the
most commonly used industrial welding process.
79
Ramazani et al. investigated the microstructure evolution of hot
rolled DP600 steel in the GMAW process. The evolution of the phase
transformation was simulated based on dilatometer experiments. The
SimWeld tool was used to analyze changes in the microstructure. The
simulation results were found to be in good agreement with the
80
experimental results. Poonnayom et al. studied the microstructure and
tensile properties of carbon steel and stainless welded using GMAW.
The welding parameters were optimized to improve the joint properties.
When the welding current was low, incomplete bonding of the metals
occurred, with low tensile strength.
3.2.4 Submerged arc welding
Fig. 14 shows a schematic diagram of the submerged arc welding
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 17, No. 7
Fig. 14 Configuration of submerged arc welding
Fig. 15 Schematic diagram of plasma arc welding
(SAW) process. SAW is a complex process that includes physical and
chemical reactions. As a result, it is very difficult to examine the entire
SAW process using a numerical simulation model.
To address the difficultly in predicting welding shape and properties,
81
Nart et al. proposed a new practical approach for simulating the SAW
process using the finite element method. The proposed approach was
compared with experimental results, and good agreement was achieved.
82
Cho et al. investigated the effect of the heat transfer in the SAW
process. The behavior of the dynamic molten pool was analyzed using
a numerical model. The numerical results and experimental results were
similar. When the torch angle was negative, a deep penetration was
produced in single DC welding.
3.2.5 Plasma arc welding
Fig. 15 shows a schematic diagram of the plasma arc welding (PAW)
process. PAW has several advantages, including a more stable,
concentrated arc and higher quality than other welding processes. The
PAW process is a novel welding process based on the traditional GTAW
process.
83
Li et al. studied an improved 3-D numerical model using the PAW
process. The 3-D model was proposed to simulate the fluid flow and
heat transfer with phase change in the weld pool during the PAW
process. Compared with experiments, the simulation model was proven
 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 17, No. 7
Fig. 16 Configuration of arc spraying
Fig. 17 Schematic diagram of plasma arc deposition
to be capable of describing the key-holing effect and the heating effect
84
of the plasma arc on the workpiece. Prasad et al. studied the weld
quality characteristics of stainless steel. PAW was carried out
successfully on various austenitic stainless steels. AISI 304L achieved
the highest tensile strength and hardness.
3.3. Arc spraying
Fig. 16 shows a schematic diagram of the arc spray process. The
coating is performed by arc spraying. Materials that can be used in the
arc spray coating include metals, ceramics, alloys and composites.
Coating quality is usually evaluated by oxide content, porosity, surface
roughness hardness and bond strength.
85
Malek et al. reviewed thermal arc spray coating. In summary,
thermal arc spray coating was determined to be an effective processing
86
method for a corrosion protection medium. Bratean studied the arc
spraying process using two wires with different chemical compositions.
The arc spraying coating provided effective corrosion protection over
the long term.
3.4. Plasma arc deposition
Fig. 17 shows a schematic diagram of the plasma arc deposition
(PAD) process. PAD is one of the physical vapor deposition techniques.
This process can be used to deposit uniformly sized nanoparticles. The
PAD process can deposit metal alloy, combinational alloy, nanoparticles
and thin films.
87
Ito et al. proposed new electrodes with platinum nanoparticles
using a pulsed PAD method. Good durability with low detection limit
JULY 2016 / 979
Fig. 18 Schematic description of laser-TIG arc welding
of the electrode was measured for the developed system. These results
showed that the PAD method can provide a superior electrode compared
88
with metal electrodes. Nikam et al. studied the relationship and
influence of deposition geometry parameters. The development of a
thermal model was accomplished using fundamental principles of
energy balance and heat transfer. The developed model was verified by
comparing with the experimental results and was found to be in good
agreement.
4. Laser-arc hybrid processes
4.1 Laser-arc hybrid welding
Interest in laser-arc hybrid welding is increasing in both academia
and industry. Laser-arc hybrid welding can be defined as the combination
of a laser heat source and an arc heat source. The concept of laser-arc
89
hybrid welding was first proposed by Steen.
The laser-arc hybrid welding has many advantages, such as improved
welding speed and weld quality, deep weld penetration, excellent gap
bridging ability, reduction of pores and cracks and good process stability.
Also, it has various welding characteristics depending on the order and
90-92
the types of the two heat sources.
4.1.1 Laser-TIG arc welding
The laser-tungsten inert gas (TIG) arc welding process is a
combination of laser welding and TIG welding, as shown in Fig. 18.
Mainly, this process is for thin gauge materials.
93
Yan et al. investigated the properties of joints produced by three
methods, laser welding, TIG welding and laser-TIG arc welding. The
phase composition and microstructure characteristics of the joints were
analyzed using microscopy and X-ray diffraction. As a result, laser
welding and laser-TIG arc welding were determined to be effective
methods for welding due to their high welding speed and good
94
mechanical properties. Song et al. studied the influence of laser pulse
waveform for laser-TIG arc welding. The type of laser used was a Nd:
YAG laser, and the materials used were AZ31B magnesium alloys. The
welding penetration values of the laser were increased with high power
density pulse (HPDP). When the plate was preheated by the TIG arc,
95
the laser could form the keyhole more easily. Tan et al. performed
laser-TIG arc welding to join Mg alloys to Zn coated steel. While the
joint could not be produced using the individual welding processes
 980 / JULY 2016
Fig. 19 Schematic diagram of laser-MIG arc welding
(laser or arc welding), acceptable joints were observed without obvious
96
defects using laser-TIG arc welding. Zhang et al. investigated the
microstructure and tensile properties of Ti-22Al-27Nb/TA15 dissimilar
joints. The laser-TIG arc welded workpiece exhibited good mechanical
properties, and the ultimate tensile strength and elongation-to-failure
were approximately 900 MPa and 4.4% at room temperature.
4.1.2 Laser-MIG/MAG arc welding
Generally, the molten materials produced by a metal inactive gas/
metal active gas (MIG/MAG) arc are used to fill the gap between the
two parts. So, a laser with highly focused intensity was combined with
MIG/MAG and its joint filling capability to enhance weldability. Fig.
19 shows the schematics of laser-MIG arc welding.
97
Gao et al. studied the mechanism and joint characteristics of laser-
MIG arc welding of AZ31 Mg alloys. The microstructure and fracture of
joints were confirmed by microscope and scanning electron microscope
(SEM). The tensile strength efficiency of joints was recovered up to 98%
of the substrate by the laser beam during the hybrid welding. Chaki et
98
al. optimized the laser-MIG arc welding process by applying three
integrated soft computing models. DOE was used, and the input
parameters were laser power, welding speeds and wires feed rate. As a
result, the most influential parameter for welding strength was confirmed
99
to be welding speed. Liu et al. studied the effects of the order of laser
and arc in laser-MAG arc welding. The effect of weld combinations on
bead shape, mechanical properties and microstructure was evaluated by
metallographic analysis and mechanical testing. Experiments were
performed under two configurations, of MAG arc-laser welding and
laser-MAG arc welding. The results of the experiments showed that
joints were produced with a fine microstructure and a better weld shape
100
by laser-MAG arc welding. Cai et al. investigated the effect of the
laser on droplet behavior in three modes, the short-circuiting, globular
and spray modes of laser-MIG arc welding. Compared with arc welding,
the droplet transfer frequency of laser-MIG arc welding in the three
modes was changed. Also, the laser promoted droplet transfer in the
short-circuiting and globular modes. However, the laser interrupted the
droplet transfer in spray mode.
4.1.3 Laser-plasma arc welding
The major characteristic of the plasma arc welding process is the
pilot arc. The stability and efficiency of the laser-plasma arc welding
101
process has been confirmed by many experiments. Fig. 20 shows a
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 17, No. 7
Fig. 20 Schematic diagram of laser-plasma arc welding
Fig. 21 Schematic description of laser-arc hybrid coating
schematic diagram of the laser-plasma arc welding process.
102
Schnick et al. investigated and compared the effects on weld
integrity between a laser and plasma arc using numerical and
experimental methods. The experimental set-up of the laser and plasma
arc was non-concentric. As a result, the efficiency of laser-plasma arc
welding was confirmed in comparison with the individual welding
103
processes. Moller et al. studied the effects on weld integrity of laser
and plasma arc. The experiments were performed with a concentric set-
up of the laser and plasma arc. The results of study showed that process
stability and welding speed were improved by combining the laser and
plasma are welding.
4.2 Laser-arc hybrid coating
Various coating processes such as cladding, deposition, and thermal
spraying are applied to enhance the mechanical properties and surface
quality of materials. Each coating process has advantages and
disadvantages. Therefore, development of new coating processes and
combinations of individual coating processes are essential to solve the
disadvantages of each process. This part reviews several laser-arc hybrid
coating processes.
104
Barroi et al. developed a process with a novel approach for high
deposition rate cladding, as shown in Fig. 21. The approach combined
the advantages of the arc and laser processes. Experiments on the
plasma melting and surface heating by laser were conducted. Process
problems were analyzed using the experimental results and a further
105
step was proposed. Theiler et al. studied the friction and endurance
of MoS /ta-C coatings deposited by laser-arc deposition. Friction tests
2
using SEM, EDX, XRD and TEM were performed to analyze the
surface. Especially at higher loads, the performance of the coating was
excellent and competitive to other coating processes.
 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 17, No. 7
Table 2 Applications of laser and arc heat sources
Hybrid laser-arc
Laser heat source Arc heat source
heat source
Machining/Cutting High Medium
Welding High High
Additive manufacturing High Medium
Coating High Very low
Forming Medium Low
5. Summary and Outlook
This paper reviewed individual processes and hybrid processes
using laser and arc heat sources from research over the last five years.
During the last 20 years, the use of laser and arc heat sources has
accelerated the development of industry. Research and development of
advanced processes using laser and arc heat sources are now in progress.
Laser heat sources in particular are being widely applied to almost the
entire range of materials in various industrial fields, because of its high
power density, highly directional and excellent focusing characteristics.
The arc heat source is mainly used in welding processes. Compared to
the laser system, the cost of an arc generator is very low and the range
106-108
of welding processes is wide. Table 2 shows the applications of
1,5,6,12,109-112
processes using laser and arc heat sources.
As mentioned above, laser and arc heat sources have many advantages,
and are essential in many manufacturing industries. In the future,
advances in individual processes using laser and arc heat sources will
result in the development of new processes and hybrid processes. For
example, laser-arc assisted hybrid machining using laser and arc heat
sources together will be proposed by this author to solve the problems
of LAM. Also, studies that focus on the commercialization of developed
techniques will be performed for process optimization, and for the
development of process devices and control systems.
ACKNOWLEDGEMENT
This research was supported by Basic Science Research Program
through the National Research Foundation of Korea (NRF) funded by
the Ministry of Science, ICT & Future Planning (No. 2016R1A2A1A0
5005492).
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