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Increase.: SPIE Vol. 1031 GCL-Seventh International Symposium On Gas Flow and Chemical Lasers (1988)
Increase.: SPIE Vol. 1031 GCL-Seventh International Symposium On Gas Flow and Chemical Lasers (1988)
Increase.: SPIE Vol. 1031 GCL-Seventh International Symposium On Gas Flow and Chemical Lasers (1988)
E. Albright
Shichan Chiang and Charlies E.
Ohio State
The Ohio
The University, Department of Welding Engineering
State University,
190, W. 19th.
190, W. Ave. Columbus,
19th. Ave. Ohio 43210
Columbus, Ohio 43210
ABSTRACT
interactions with
Light interactions materials in
with materials material processing
laser material
in laser occur by
operations occur
processing operations variety of
by a variety of
mechanisms depending on
mechanisms depending on the material being processed,
the material wavelength of
the wavelength
processed, the of the laser light,
the laser gaseous
the gaseous
light, the
and the physical state of the
environment, and
environment, the material surface. The high reflectivity of
material surface. of metals limits the
metals limits the
fraction of
fraction the beam
of the absorbed by
power absorbed
beam power by the surface.
metal surface.
solid metal
the solid For metals in the
For metals the solid state,
solid state,
increases as
reflectivity increases
reflectivity the wavelength of
as the of the laser light
the laser and the
light and conductivity of
electrical conductivity
the electrical of the metal
the metal
reflectivity of
increase. The reflectivity
increase. metals is
of metals is reduced heating to
upon heating
reduced upon to the melting point,
the melting and further
point, and reduced
further reduced
melting. At
upon melting. At high densities the
power densities
high power the liquid surface is
metal surface
liquid metal is heated so quickly
heated so that very
quickly that rapid
very rapid
vaporization occurs.
vaporization occurs. The recoil force
The recoil produced by
force produced theevaporation
by the depression in
causes aa depression
evaporation causes the
in the
liquid /vapor interface.
liquid/vapor interface. The "keyhole" resulting
The from this
resulting from depression allows
this depression for multiple
allows for and
reflections and
multiple reflections
thus absorption into
thus increases beam absorption the liquid.
into the The vaporized
liquid. The metal above
vaporized metal the liquid
above the can cause
surface can
liquid surface cause
attenuation of the
attenuation beam. Both plasma absorption and
the beam. fine particle
and fine theory have
scattering theory
particle scattering proposed
been proposed
have been
to account for this
account for attenuation. The
beam attenuation.
this beam attenuation is
The attenuation is strongly affected by
strongly affected shielding gas
by shielding type and
gas type and
pressure. In
pressure. In the cutting the
the laser cutting interacts with
the beam interacts the material
with the through aa high
material through angle of
high angle of incidence.
incidence.
Under these conditions the the degree of beam
degree of important.
polarization becomes important.
beam polarization
1. INTRODUCTION
1.
(welding, cutting,
Material processing (welding,
Material etc.) using
treatment, etc.)
cutting, surface treatment, focused and
both focused
using both high
unfocused high
and unfocused
power laser
power is widely
laser beams is accepted by
widely accepted modern industry.
by modern The nature
industry. The of laser
nature of -material interactions
beam-material
laser beam
is complicated
is the changes
by the
complicated by the beam causes in
that the
changes that the material.
in the material.
The
The application light in
application of laser light material processing
most material
in most operations is
processing operations achieved by
is achieved laser
converting laser
by converting
heating process
The heating
light into heat. The is illustrated
sequence is
process sequence Fig. 11 through
in Fig.
illustrated in 4. Laser beam - material
through 4.
interactions depend
interactions large extent on
to a large
depend to on the physical state
the physical of the
state of material surface.
the material interactions
These interactions
surface. These
can thus be
can thus subdivided into
be subdivided the following categories:
into the categories:
» Solid
* state
Solid state
* Surface
* melting
Surface melting
Rapid evaporation,
* Rapid penetration and
evaporation, deep penetration formation
plasma formation
and plasma
For low laser
For low beam power
laser beam and short
power and time irradiation,
short time there is
irradiation, there very shallow
is aa very solid surface
shallow solid layer
surface layer
the laser (Fig.
heated by the
heated 1). As the
(Fig. 1). exposure time
the exposure increases, the
time increases, liquid phase
the liquid will be
phase will formed (Fig.
be formed 2).
(Fig. 2).
solid-liquid
The solid interface propagates
-liquid interface into material
propagates into at a speed
material at dependent on
speed dependent the process
on the e.g.,
variables, e.g.,
process variables,
laser power, process
laser beam power, travel speed,
process travel etc. The speed
speed, etc. propagation of
of propagation
speed of of the solid-liquid
the solid interface is
-liquid interface is
also limited by the
also limited properties as
thermal properties
the thermal well as
as well the geometric
as the configuration of the
geometric configuration More
material. More
the material.
rapid heating by
rapid the laser
by the beam will
laser beam cause vaporization
will cause (Fig. 3),
vaporization (Fig. and/or
3), and /or plume formation (Fig.
plume formation 4).
(Fig. 4).
In all
In cases, the
all cases, state of the material is
physical state
the physical is controlled beam heating.
controlled by beam The physical
heating. The state of
physical state of
the material,
the material, in turn, controls
in turn, the nature
controls the of the
nature of beam-material
the beam -material interactions. mechanisms of
interactions. The mechanisms beam--
of beam
material interactions are
material interactions understood. The
fully understood.
not fully
are not The main difficulty arises at
difficulty arises temperatures.
elevated temperatures.
at elevated
the thermal
Not only do the
Not change, but the newly generated material
thermal properties of material change, states affect
material states the
affect the
absorption of laser energy and and complicate the physics of
the physics process.
the process.
of the
In
In this paper, the
this paper, current state
the current of understanding
state of of laser
understanding of beam-material
laser beam- interaction in
material interaction material
in material
is reviewed.
processing is laser processing
reviewed. Applications of laser are briefly
processing are summarized.
briefly summarized.
2. SOLID
2. STATE INTERACTIONS
SOLID STATE
engineering materials
Most engineering power Nd:YAG or COp
transmit high power
materials do not transmit CO2 laser beams. The beam is
laser beams. either
is either
reflected
reflected or absorbed. The
or absorbed. the reflectivity,
The higher the the lower
reflectivity, the the absorptivity
lower the and thus
absorptivity and the lower
thus the the
lower the
of laser
heating efficiency of
heating irradiation. Most non
laser irradiation. non-metals high absorptivity
have aa high
-metals have laser
absorptivity for high power laser
beams. Most metals, however,
Most metals, have a ahigh
however, have reflectivity to
highreflectivity C02 laser
to CO2 light (10.6
laser light urn), but
(10.6 um), lower
but lower
reflectivity to
reflectivity light (1.06
to Nd:YAG laser light urn). Nd:YAG lasers are preferred over CO2
(1.06 um). C02 lasers inin processing
processing
as aluminum
materials, such as
high reflectivity materials, copper.
and copper.
aluminum and
SPIE
522 //SP /E Vol. GCL—Seventh
1031 GCL-
Vol. 1031 InternationalSymposium
Seventh International onGas
Symposiumon Flowand
GasFlow ChemicalLasers
andChemical (1988)
Lasers(1988)
common application
A common of laser
application of of solid
processing of
laser processing metals is
solid metals surface hardening
is surface steels.
hardenable steels.
hardening ofof hardenable
Coatings are
Coatings employed to
are employed absorptivity. A rapid
increase absorptivity.
to increase rapid heating rate is
heating rate created by
is created the laser
by the beam
laser beam
irradiation. Rapid cooling is
Rapid cooling is provided the conduction
provided by the heat to
conduction of heat the cool
to the metal under
cool metal heated
the heated
under the
layer.
layer. This short
This short time thermal cycle
time thermal produces quench
cycle produces hardening in
quench hardening in thin
thin layers on the
layers on surface of
the surface the
of the
treated steel.
steel.
This form
This has been
form of shallow melting has "conduction mode"
called "conduction
been called although stirring
melting, although
mode" melting, probably
is probably
stirring is
the predominant
the mode of
predominant mode of heat transfer in the
heat transfer molten pool8.
the molten penetration welding
Shallow penetration
pool8 . Shallow welding is common
is a common
process employing
process melting.
employing conduction mode melting.
The
The shallow depth of
shallow depth providesa ameans
melting provides
of melting material surface
modifyingmaterial
meansof ofmodifying while
properties while
surface properties
preserving the properties
preserving the the bulk
properties of the material. The surface modification can be performed autogeneously
bulk material. autogeneously
(i.e., glazing), by4 akdding alloy elements (surface alloying), or by overlaying dissimilar materials materials
(surface c,l2adding) ' Recent developments in laser surcing are the production of a ceramic
. ceramic
coatings"' '4 the modification of a plasma- sprayed coatings These techniques of laser surface
laser surface
modification are used
modification are used to enhance wear, and
corrosion, wear,
enhance corrosion, insulation resistance.
surface insulation
and surface can
process can
resistance. The process
be used
also be
also to decrease the porosity
used to surface coating
of surface
porosity of layers.
coating layers.
AND IONIZATION
4. VAPORIZATION AND
4.
Heating, melting,
Heating, and violent evaporation
melting, and under conditions
developed under
evaporation are developed high power
of high
conditions of laser
density laser
power density
irradiation.
irradiation. A plume
A above the
appears above
plume appears irradiated material
the irradiated surface. The generation of
material surface. phenomena
these phenomena
of these
produces complex
produces complex laser beam-material
laser beam- interactionswhich
material interactions can not
whichcan be explained
not be the simple
by the
explained by reflection
simple reflection
model.
To organize the discussion,
organize the discussion, this section is divided
section is into two
divided into parts, deep
two parts, penetration laser
deep penetration and
welding and
laser welding
laser cutting. These processes are
These processes the most
are the common applications
most common of laser
applications of processing in
laser processing high power
the high
in the power
melting and
involve melting
range. Both processes involve evaporation.
and evaporation.
There are, significant differences
are, however, significant beam-material
the beam
in the
differences in -material interactions between the
interactions between processes.
two processes.
the two
4.1. Deep
4.1. Penetration Welding
Deep Penetration
SPIEVol.
SPIE GCL—Seventh
10311031
Vol. International
GCL- Seventh Symposium on
International Symposium on Chemical
Gas Flow and Gas Flow and(1988)
Lasers / 523 Lasers (198
Chemical
where
where P(Z)
P(Z) == the
the pressure
pressure or stress above
or stress above the
the ambient
ambient pressure
pressure causing
causing deep
deep penetration
penetration
ZZ == penetration
penetration depth
S
S == surface tension of
surface tension of liquid
liquid-vapor
-vapor interface
RZ
RZ == hole
hole radius
radius at
at level
level ZZ
dg
ds = density
= density of
of liquid
liquid metal
g
g a= gravity
gravity constant
P(f)
P(f) == Pressure
Pressure produced
produced by fluid flow resistance
fluid flow resistance
This model predicts
This model predicts pressures
pressures ininthe
thecavity
cavity(P(Z))
(P(Z))totobebe2 *10
2*10"~2 atms for
-2 atms for 11 cm
cm penetration
penetration of
of iron
iron under
under
static conditions (P(f)
static conditions (P(f) == 0).
0).
The P(Z) term
The P(Z) term was
was modified by Klemens15
modified by Klemens 15 by
by considering
considering the
the vapor
vapor flow
flow inside
inside the
the key hole.
hole. Using his
his
model and
model and assuming
assuming that
that this
this contribution
contribution of vapor flow
of vapor flow is
is constant
constant at any
any depth
depth in
in the
the cavity,
cavity, the
the
maximum pressure
maximum pressure in
in aa 11 cm
cm deep cavity is
deep cavity is less
less than
than U*10
4 *10 -2 atm.
atm. The experimental
The experimental results
results of
of Miyamoto
Miyamoto et
et
al 1b
al 1 confirm
confirm this
this general
general level pressure. They
level of pressure. They also
also commented
commented that
that iron
iron at
at aa temperature
temperature of
of 2200
2200 CC
has an
has an equilibrium
equilibrium vapor
vapor pressure
pressureofof2.7
2.7*10 atm. This
*10 -2 atm. temperature corresponds
This temperature corresponds to
to temperatures
temperatures of
of 2170
2170
C to
C to 2220
2220 CC measured
measured in
in keyholes
keyholes by Schawer
Schawer et
et al
al in
in electron
electron beam
beam cavities17.
cavities''. This strongly
strongly suggests
suggests
that the
that the recoiled
recoiled vapor
vapor pressure
pressure is the main
is the main factor
factor sustaining
sustaining thethe cavity
cavity or
or key hole
hole and
and causing
causing deep
deep
penetration
penetration in in laser
laser welding.
welding.
Above 1 kW
Above 1 kW the
the penetration
penetration depth in high
depth in high power
power laser
laser welding
welding with
with aa focused
focused beam
beam increases
increases as
as the
the beam
beam
power
power raised
raised to an
an exponent between 0.7 and
and 0.8
0.8^° (Fig. 7).
(Fig. 7).
U.1.2.
4.1.2. Factors
Factors Increasing
Increasing Power Input Efficiency.
Efficiency. The
The deep penetration mode
deep penetration mode laser
laser welding is associated
associated
with
with anan iimprovement
rove20ent inin beam absorption.
beam absorption. The cavity traps
The cavity traps the
the beam
beam byby a aprocess
process ofof multiple
multiple
reflections'°»
reflections 1 9,20^ Each
,
reflection provides
Each reflection provides absorption
absorption of
of aa fraction
fraction of
of the
the beam
beam(about
(about1313$).
%). Both
Both
process
process efficiency (absorption) and
efficiency (absorption) and penetration
penetration depth are
are increased
increased by
by this
this process.
process.
Another effect
Another effect that
that contributes
contributes to
to the
the increase
increase ininabsorption
absorptionisisthetheso-
so-called "enhanced coupling"
called "enhanced coupling" of
of
the plume '. AA cloud
the plume21'22. cloud of
of glowing
glowing hot
hot gas
gas called
called the
the plume
plume is
is formed
formed above
above the
the surface
surface of
of the
the material
soon
soon after vaporization begins. The plume absorbs
The plume absorbs laser
laser power
power and
and transfers
transfers the
thepower
powerbybyre-
re-radiating
radiating
short
short wavelength (including visible)
wavelength (including light to
visible) light to the
the material
material surface.
surface. The short wavelength
The short wavelength light
light is
is
absorbed
absorbed more
more efficiently than the
efficiently than the incoming
incoming beam
beam (Fig.
(Fig. 5).
5).
Inert shielding
Inert shielding gases
gases are commonly employed
are commonly employed to avoid oxidation
to avoid oxidation or contamination of
or contamination of molten
molten metal.
Weal.
These gases
These gases also
also influence
influence the
the absorption
absorption and
and penetration
penetrationdepth,
depth, especially
especiallyininkeyhole
keyholemode
modeweldingll'
welding7 ' 23 ..
The process
The process efficiency
efficiency (absorptivity)
(absorptivity) as as aa function
function ofof shielding
shielding gas compositions
compositions for pulsed
pulsed laser spot
spot
welding is shown
welding is shown in
in Fig.
Fig. 9i9.
9 19 . With pure helium
With pure helium the
the process
process efficiency
efficiencycan
canexceed
exceed3030^.
%. efficiency
The efficiency
does not
does not exceed
exceed 15%
15% when argon is is used.
Helium shielding gas
Helium shielding gas also
also provides
provides better
better penetration.
penetration. Chennat23
Chennat23 showed
showed that
that penetration
penetration in
in laser
laser
spot welding
spot is proportional
welding is proportional to
to the
the thermal
thermal conductivity
conductivity of
of the
the shielding
shielding gas
gas or
or gas
gas mixtures
mixtures (Fig.
(Fig. 10).
10).
C02 shielding gas
CO shielding
2
gas gives
gives deeper
deeper penetration
penetration than
than expected
expected due
due to
to dissociation
dissociation effects23.
effects2^.
4.1.3. Beam Attenuation
4.1.3. Beam Attenuation Effects.
Effects. Although
Although most
most of the laser
of the laser power isis absorbed
absorbed by the
the work
work piece
piece during
during
keyhole
keyhole mode
mode welding, the initial
welding, the initial incident
incident laser
laser beam
beam power
power does
does not
not reach
reach the
the bottom
bottom of
of the
the vapor
vapor cavity
cavity
(see
(see Fig. 6). The
Fig. 6). The beam is attenuated
beam is attenuated as
as it
it passes
passes through
through the
the cavity.
cavity. The value
value of the power density at
the bottom
the bottom of
of the
the cavity
cavity is
is critical.
critical. At this point
At this point the
the surface
surface tension
tension and
and hydrostatic
hydrostatic forces
forces combine
combine
to
to give
give aa maximum
maximum value
value to
to the forces opposing
the forces opposing penetration. The power density
density at
at this
this point
point must
must sustain
sustain
sufficient
sufficient vaporization
vaporization toto produce the recoil
produce the recoil force
force to
to balance
balance the
the restoring
restoring forces.
forces.
The power density
The power density at
at the
the bottom
bottom of
of vapor
vapor cavity,
cavity, IZ,
Iz> is
is associated
associated with
with this
this critical
critical evaporation
evaporation
rate.
rate. In
In general, Iz can be written
general, IZ written as:
as:
IIZz == I exp (-aZ)
(-aZ) (3)
(3)
where
where I == the incident laser power density
I
Z == penetration depth
a =a the
a the attenuation factor
The larger
The larger the
the attenuation
attenuation factor,
factor, the
the shallower
shallower the
the penetration
penetration depth.
depth. It is well known
known that
that the
the
penetration
penetration ofof laser
laser beam
beam welding
welding at atmospheric pressure
at atmospheric pressure is
is much lower than
much lower than that
that of electron
electron beam
beam
welding
welding at same power
at same power level.
level. The attenuation
The attenuation factor
factor in high power
in high power laser
laser welding
welding is
is blamed
blamed for
for the
the
decreased penetration.
penetration.
Duley2^ showed
Duley24 showed that
that the beam reached
reached the
the diffraction limited spot size in the bottom of drilled
diffraction limited drilled holes
holes
in quartz.
quartz. ByBy extending
extending his
his model
model to
to CO2
C02 laser
laser welding,
welding, he
he was
was able
able to
to establish
establish attenuation
attenuation factors
factors of
between 0.43
between 0.43 to
to 0.86
0.86 cnr* for the
cm for the process.
process.
524
524 //SPIE
SPIEVol.
Vol. 1031
1031 GCL-
GCL—Seventh Internationa/Symposium
Seventh International Symposiumon
onGas
Gas Flow
Flow and
and Chemical
Chemical Lasers
Lasers (1988)
(1988)
where aay
where aav is the average
is the attenuation factor,
average attenuation and W is
factor, and incident laser
the incident
is the power into
laser power the cavity.
into the The
cavity. The
equation
equation shows that as
shows that laser power
as laser increases, the
power increases, effect is
attenuation effect
the attenuation decreased, and
is decreased, and thus the
thus the
depth is
penetration depth increased.
is increased.
Miyamoto et
Miyamoto et aí25 attenuation factor in the
investigated the attenuation
al25 investigated welding for
keyhole mode laser welding
the keyhole 304
thick 304
for thick
stainless steel plates. Th^ir
stainless Their results showed attenuation factor
the attenuation
showed that the laser beam
for aa laser
factor for of 66 kW
power of
beam power
at pressure of
at aa vacuum pressure -3 torr
10"3
of 10 0.5 cm"
was 0.5
torr was cm-1, while at
1 , while at atmospheric pressure it
atmospheric pressure was 11 to 1.5
it was cm"11..
1.5 cm
4.1.4. Plasma Plume
4.1.4. Plasma Theory. Plumes
Plume Theory. glowing gas
Plumes of hot glowing develop above
gas develop bove the material during
the material beam
laser beam
during laser
irradiation. At low power
irradiation. densities the
power densities are orange
plumes are
the plumes white'. At
to white'.
orange to densities the
At high power densities plumes
the plumes
are blue. plume is
The blue plume called the
is called plume".
"plasma plume
the "plasma This term implies
". This the gas in the
that the
implies that the plume is
plume is
at a high
at temperature for
enough temperature
high enough ionization of
significant ionization
for significant of atoms. lonization implies
atoms. Ionization of
presence of
implies the presence
positive ions
positive and free
ions and electrons. Scattering and
free electrons. absorption of
and absorption the incoming
of the beam by
incoming beam free electrons
by free are
electrons are
proposed as
proposed mechanism to
as a mechanism for decreased
account for
to account penetration when
decreased penetration plumes are
large plumes
when large observed. At high
are observed.
power this mechanism
levels this
power levels mechnism isis probably valid. At
probably valid. At lower levels, the
power levels,
lower power validity of
the validity this mechanism
of this is
mechanism is
questionable. Chennat spectroscopy to
used spectroscopy
Chennat235 used to show iron is
that iron
show that the only
is the species in
ionized species
only ionized in both argon
both argon
and helium plumes
and low power
plumes in low laser spot
power laser welding of
spot welding steel. The degree of
of steel. ionization was
of ionization at most
was at only aa
most only
percent.
few percent.
few
Herziger
Herzig%r26p proposed
2
osed that
absorption6,' 2 :?' 2^. P7 The
absorption
formation ofofa aplasma
the formation
that the
the metal
electrons in the
The electrons particles are
vapor particles
metal vapor
with"inverse
associatedwith
plasmais isassociated bremsstrahlung"
"inverse bremsstrahlung"
accelerated by absorbing laser beam
are accelerated beam
energy56,26.27
photon energy '» 2b » 2 '. The plasma plume develops as
plume develops phenomenon when
thermal phenomenon
as aa thermal metal vapor
the metal
when the temperature
vapor temperature
ionization.
is high enough to produce ionization.
The
The plasma continues to
plasma continues to absorb the laser
absorb the increasing its
laser energy by increasing electron density
its electron the plasma
when the
density when plasma
oscillation frequency,
frequency, wp, lower than
wp , is lower the frequency
than the of the
frequency of incident laser
the incident light, ww as
laser light, by:
given by:
as given
w* >> wp Ne/eQ
(e2 Ne
wp == (e2 /eo me)1 /2
me ) 1/2 (5)
(5)
where
where Ne =
= free electron density
e s= charge
electron charge
eQ
eo == the vacuum
dielectric permitivity of the
dielectric vacuum
nig
me =
= electron mass
w, the
wp is equal or larger than w,
When Wp laser light
the laser will be
light will reflected by
be reflected the plasma
by the and the
plasma and laser power
the laser to
power to
the material is
the Because the
blocked. Because
is blocked. from metal
generated from
the plasma is generated vapor, there
metal vapor, threshold laser
is aa threshold
there is laser
formation which
power intensity for the plasma formation is aa function
which is of following
function of factors:
following factors:
** Thermal properties
Thermal vapor
properties of vapor
** Incident laser beam power
Incident density
power density
** Evaporation rate of the
Evaporation rate material
base material
the base
** light
Wavelength of laser light
relationship of plasma threshold
A relationship intensity with input
threshold intensity power for
laser power
input laser is illustrated
steel is
for steel Fig.
in Fig.
illustrated in
11 b . The
116. power density
The power to form
required to
density required plasma is
form aa plasma slightly higher
only slightly
is only than that
higher than required to
that required cause
to cause
vaporization. Thus the power
Thus the density above
power density the plasma
above the threshold intensity
plasma threshold has aa limited
intensity has effect in
limited effect in
penetration.
increasing penetration.
increasing
At very high
At power densities
high power the plasma
densities th2 will move
plasma will beam toward
the beam
move up the the laser
toward the beam source
laser beam and will
source and will
absorb the incident
absorb the power .
laser power'.
incident laser Depending on
Depending the shielding
on the gas composition,
shielding gas power density
composition, power and
density and
plume is
wavelength of the laser beam the plume raised to
is raised above the
distance above
to aa distance surface until
material surface
the material power
the power
until the
the expanding beam is
density of the too low
is too to sustain
low to plasma. At
sustain aa plasma. this point
At this the plasma
point the extinguished,
is extinguished,
plasma is
and second plasma
and a second plume is
plasma plume generated at
is generated the material
at the surface. The
material surface. The periodic formation of plasma
formation of plume
plasma plume
interupts the continuous
interupts the input to
laser power input
continuous laser the material'.
to the This phenomenon occurs
material6 . This lower power
at much lower
occurs at power
helium as
replaces helium
densities when argon replaces gas.
shielding gas.
as aa shielding
4.1.5. Particle
4.1.5. Particle Scattering Theory. occurs when the
Scattering occurs
Theory. Scattering electromagnetic wave
incident electromagnetic
the incident interacts
wave interacts
with a volume
with of dispersed
volume of particles. The
dispersed particles. scattered light
The scattered power is
light power dependent on
is dependent the particle
on the size,
particle size,
wavelength, scattered
incident wavelength,
incident the electromagnetic
and the
scattered direction and of the
properties of
electromagnetic properties particles.
the particles.
The scattering effect
he scattering effect of particles from material vapor
condensing from
particles condensing first proposed
was first
vapor was Matsunawa et
by Matsunawa
proposed by
al2 -30..
al2*5""30 Since levels of ionization
observed very low levels
Since they observed welding, they
Nd:YAG welding,
ionization in Nd:YAG that beam
proposed that
they proposed beam
SPIE Vol.
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Symposium on and Chemical
Flow and Lasers (1988)
Chemical Lasers 525
(1988)// 525
4.2.1.
4.2.1. Formation of of Kerf
Kerf Striations.
Striations. The striation formation
The striation formation onon the
the kerf surface is
kerf surface one of
is one of the
the
characteristics
characteristics in laser cutting.
in laser cutting. When a high
When a high power
power laser
laser is
is used
used aa keyhole
keyhole is
is developed
developed through
through the
the
thickness
thickness of workpiece.
workpiece. The coaxial assist
The coaxial assist gas
gas pushes
pushes the
the liquid
liquid metal
metal out
out of
of the
the keyhole. This action
leaves
leaves aa cavity
cavity with
with aa diameter
diameter larger
larger than
than laser
laser spot
spot size.
size. The laser beam must
The laser must move
move beyond
beyond the
the
boundary
boundary of this cavity
of this cavity to
to further
further interact
interact with
with the
the metal.
metal. Thus aa periodic
periodic ignition
ignition and
and propagation
propagation
sequence creates
sequence striations between cavities.
creates striations cavities.
4.2.2. Polarization. The
4.2.2. Polarization. beam-material
The beam- material interactions
interactions inin laser
laser cutting
cutting are
are similar
similar to
to laser
laser welding
welding with
with
one important exception.
one important exception. Polarization
Polarization ofof the
the beam
beam does
does not
not have major effect
have a major effect on
on laser
laser welding
welding
performance.
performance. Polarization
Polarization of the beam,
of the however, has
beam, however, has an
an important
important effect
effect on
on laser
laser cutting
cutting performance.
performance.
In laser cutting,
In laser cutting, the
the beam
beam interacts
interacts with
with the
the material
material through
througha ahigh
highangle
angleggfof incidence,
incidence, as
as shown
shown in
in
Fig. 13. Under
Fig. 13. these conditions
Under these conditions beam
beam polarization
polarization affects
affects beam
beam absorptivity38
absorptivity ,3'.' 39 . When
When the
the direction
direction of
beam
beam polarization
polarization isis parallel
parallel toto the
the cutting
cutting direction,
direction, absorption
absorption isis maximized.
maximized. A smooth, straight, and
smooth, straight, and
minimum
minimum kerf width out
kerf width cut isis produced.
produced. Depth
Depth ofof cut
cut is
is also
also maximized
maximized under
under these
these conditions.
conditions. If thethe
direction
direction of polarization is
of polarization is at
at an angle to
an angle the cutting
to the cutting direction,
direction, thethe result
result cancan be
be a rough and
and tilted
tilted
kerf of
kerf of increased
increased width.
width. To avoid cutting
To avoid cutting quality
quality variation
variation with
with cutting
cutting direction,
direction, aa circular
circular polarizer
polarizer
beam is
beam is commonly
commonly used39.
used 39 . Many devices are
Many devices are ..:sailable39
available 39 totoconvert
converta ahighly
highly linear
linear polarized
polarized beam
beam into
into aa
beam
beam with
with a high degree of polarization symmetry.
symmetry.
5.CONCLUSION
5.CONCLUSION
Key points
Key points for
for laser
laser processing:
processing:
1.
1. Solids
Most nonmetals have
Most nonmetals have aa relatively
relatively high
high absorptivity
absorptivity to to high
high power
power laser
laser light.
light. TheThe high
high
reflectivity
reflectivity of
of metals limits the
metals limits the fraction
fraction of
of the
the beam
beam power
power absorbed
absorbed by the
the solid
solid metal surface.
surface.
For metals
For metals in
in the
the solid
solid state,
state, reflectivity
reflectivity increases
increases as
as the
the wavelength
wavelength of
of the
the laser
laser light
light and
and the
the
525 SPIEVol.
526 //SPIE Vol. 1031
1031 GCL-
GCL—Seventh InternationalSymposium
Seventh International Symposiumon
onGas
Gas Flow
Flow and
and Chemical
Chemical Lasers
Lasers (1988)
(1988)
1. J. F.
1. J. "Interaction of
Ready, "Interaction
F. Ready, of high -power laser radiation
high-power materials",
with materials
radiation with ", Industrial Applications of
Industrial Applications of
Lasers.
Lasers, P. 336-357.
P. 336 Academic Press,
-357. Academic Press, N.N. Y. (1978).
Y. (1978).
2. D. M.
2. D. Roessler, "An
M. Roessler, introduction to
"An introduction processing of
laser processing
the laser
to the materials",
of materials in The
", in industrial laser
The industrial laser
annual 1988 Edition,
handbook, 1988
annual handbook. Edition, D. Belforte and
D. Belforte M. Levitt,
and M. PennWell Books,
ed. PennWell
Levitt, ed. Tulsa, OK
Books, Tulsa, USA. P.
OK USA. 16-30
P. 16 -30
(1988).
(1988).
3. Y.
3. Arata, and
Y. Arata, I. Miyamoto,
and I. "Some fundamental
Miyamoto, "Some properties of
fundamental properties high power
of high power laser beam as
laser beam as aa heat source
heat source
2) ",in
(report 2)",
(report in Plasma. Electron && Laser
Plasma, Electron Beam Technology,
Laser Beam Technology, ASM, Park, OH,
Metals Park,
ASM, Metals USA, P.
OH, USA, 234 -244
P. 234 (1986).
-244 (1986).
4. Bloyce, and
A. Bloyce,
4. A. and T. Bell, "Laser
T. Bell, Engineering",
Surface Engineering
"Laser Surface ", in The industrial laser
The industrial annual handbook,
laser annual 1988
handbook, 1988
Edition, Belforte and
Edition, D. Belforte Levitt, ed.
M. Levitt,
and M. PennWell Books,
ed. PennWell Tulsa,OK.
Books, Tulsa, USA.P.P.6161-68
OK.USA. (1988).
-68 (1988).
5. T.
5. VanderWert, "Low
T. VanderWert, power (1
"Low power (1 kW and below)
kW and welding",
laserwelding
below) laser ", in The Industrial
in The Laser Annual
Industrial Laser Handbook.
Annual Handbook,
Edition, D.
1986 Edition,
1986 Belforte and
D. Belforte Levitt, ed.
M. Levitt,
and M. ed. Pennwell Tulsa, OK.
Books, Tulsa,
Pennwell Books, USA.P.P.5858-68
OK. USA. (1986).
-68 (1986).
6. G.
6. G. Herziger,
Herziger, "The influenceofoflaser-
"The influence laser-induced plasma ononlaser
induced plasma processing",
materialsprocessing
lasermaterials ", in The
in The
Industrial Laser Annual Handbook,
Industrial Edition, D.
1986 Edition,
Handbook, 1986 D. Belforte and M.
Belforte and Levitt, ed.
M. Levitt, Pennwell Books,
ed. Pennwell OK.
Tulsa, OK.
Books, Tulsa,
USA. P.
USA. 108-115
P. 108 (1986).
-115 (1986).
7. R. S.
7. R. Arnot, and
S. Arnot, C. E.
and C. "Plasma plume
E. Albright, "Plasma in pulsed
effects in
plume effects carbon dioxide
pulsed carbon laser spot
dioxide laser welding",
spot welding ",
ICALEO'83, Vol. 38,
ICALEO'83, LIA, Vol. 51-58
P. 51
38, P. (1983).
-58 (1983).
8. J.
8. Mazumder, "An
J. Mazumder, overview of
"An overview of transport phenomena inin laser
transport phenomena processing",
materialsprocessing
lasermaterials Proceedings of
", Proceedings of
LAMP'87. Osaka, Japan.
LAMP'87, Osaka, Japan. Paper (1987).
1B02 (1987).
Paper 1B02
9.
9. W. M. Steen,
W. M. "Laser cladding,
Steen, "Laser alloying, and
cladding, alloying, melting",
and melting in The
", in Industrial Laser
The Industrial Handbook, 1986
Annual Handbook,
Laser Annual 1986
Edition, D.
Edition, D. Belforte, and Levitt, ed.
M. Levitt,
and M. Tulsa, OK.
Pennwell, Tulsa,
ed. Pennwell, OK. USA. 158-174
USA. P.P.158 (1986).
-174 (1986).
10. A.
10. A. A. Mangaly, and M.
A. Mangaly, M. A. Everett, "Industrial
A. Everett, applications of
"Industrial applications cladding",
laser cladding
of laser ", inin The Industrial
The Industrial
Laser Annual Handbook,
Laser Annual Edition, D.
Handbook, 1988 Edition, Belforte and
D. Belforte and M. Levitt, ed.
M. Levitt, ed. Pennwell, Tulsa, OK.
Pennwell, Tulsa, USA. P.P. 6969-74
OK. USA. -74
(1988).
(1988).
11. N.
11. Yasunaga, A.
N. Yasunaga, Obara, S.
A. Obara, Mineta, and
S. Mineta, M. Ikeda,
and M. formation on
layer formation
"Ceramic layer
Ikeda, "Ceramic on metal surfaces by
metal surfaces gas
by gas
reaction assisted CO2 COp laser treatment",
laser treatment ", Proceedings of of LAMP'87, Japan. P.
Osaka, Japan.
LAMP'87, Osaka, 485-490
P. 485 (1987).
-490 (1987).
12. K.
12. Tsukamoto, F.
K. Tsukamoto, Uchiyama, M.
F. Uohiyama, Okutomi, S.
M. Okutomi, Shiratori, and
S. Shiratori, and Y.Y. Ohno, "A new
Ohno, "A ceramics coating
new ceramics technique
coating technique
C02 laser
using CO2 Proceedings of
laser",", Proceedings of LAMP'87.
LAMP'87, Osaka, Japan. P.
Osaka, Japan. P. 491 (1987).
-496 (1987).
491 -496
13. N.
13. Iwamoto, N.
N. Iwamoto, Umesaki, and
N. Umesaki, and S. Endo, "Surface
S. Endo, modification of
"Surface modification plasma-sprayed
of plasma- sprayed ceramic coatings by
ceramic coatings by
laser beam", Proceedings of
beam ", Proceedings of LAMP'87.
LAMP'87, Osaka, Japan. P.
Osaka, Japan. 503-508
P. 503 (1987).
-508 (1987).
14. N.
14. Iwamoto, N.
N. Iwamoto, Umesaki, Y.
N. Umesaki, Katayama, and
Y. Katayama, and H.H. Kuroki, "Surface treatment
Kuroki, "Surface plasma-sprayed
treatment ofofplasma- ceramic
sprayed ceramic
coatings by
coatings laser beam
by laser in Thermal
beam",", in Spray: Advances
Thermal Spray; Advances in Coatings Technology,
in Coatings ASM, Metals
Technology, ASM, Park, OH.
Metals Park, P.357-
OH. P.357-
(1988).
364 (1988).
364
15. P.
15. G. Klemens, "Heat
P. G. balance and
"Heat balance conditions for
flow conditions
and flow electron beam
for electron and laser
beam and welding",
laserwelding Journal of
", Journal of
Applied Physics,
Applied Physics, Vol. No. 5,
47, No.
Vol. 47, 2165 -2174
P. 2165
5, P. (1976).
-2174 (1976).
16. I.
16. Miyamoto, H.
I. Miyamoto, Maruo, and Y.
H. Maruo, Y. Arata, "The role
Arata, "The assist gas
role of assist gas in C02 laser
in CO2 welding",
laser welding ICALEO'84, LIA.
", ICALEO»84, LIA.
Vol. 44,
Vol. P. 68
44, P. (1984).
-75 (1984).
68 -75
17. D.
17. D. A. Sohawer, W. H.
A. Schawer, H. Giedt, and S. M.
and S. "Electron beam
M. Shintaku, "Electron beam welding temperature
cavity temperature
welding cavity
distribution on pure metals
on pure alloys",
and alloys
metals and Journal, Vol.
", Welding Journal, Vol. 57, No. 5,
57, No. 127s-133s
P. 127s
5, P. (1978).
-133s (1978).
18. C,
18. Banas, "High
C. Banes, power laser
"High power welding",", in
laser welding in The Industrial Laser
The Industrial Annual Handbook.
Laser Annual Handbook, 1986 Edition, D.
1986 Edition, D.
Belforte and M. LevittLevitt ed. Pennwell Books,
ed. Pennwell Tulsa, OK.
Books, Tulsa, USA. P.P. 6969-86
OK. USA. (1986).
-86 (1986).
19. C.
19. C. E.
E. Albright, "Pulsed CO2
Albright, "Pulsed welding",", in
laser welding
C02 laser Trends in
in Trends Welding Research.
in Welding Research, ASM, Park, OH.
metals Park,
ASM, metals OH.
P.653-665
P.653 (1981).
-665 (1981).
20. Y.
20. Arata, and
Y. Arata, I. Miyamoto,
and I. Miyamoto, "Some properties of
fundamental properties
"Some fundamental high power
of high beam as
laser beam
power laser as aa heat source
heat source
SP Vol.1031
SPIE/EVol. GCL- SeventhInternational
1031GCL—Seventh Symposiumon
InternationalSymposium GasFlow
onGas and Chemical
flow and (1988)// 527
Lasers(1988)
Chemical Lasers 527
LASER
LASER
BEAM LASER
BEAM
\ \ \\ f / \
REFLECTION\
REFLECTIONS \
REFLECTIONS \ \\ / /
/REFLECTION
REFLECTION
\\
\ \\ /
\ \\/
/ \
I
V,/../,./:://////////////// SURFACE
CONDITION MOLTEN
LIQUID
/LIQUID
HEATING
CONDUCTION HEATING PENETRATION
SHALLOW PENETRATION
Fig. 1. Laser
Fig. 1. Laser beam-
beam-material interactions
material interactions Fig. 2.
Fig. 2. Laser
Laser beam-
beam-material
material interactions
interactions
—
-- Solid state
Solid state —•
-- Surface
Surface melting
melting
\\ \l If
\\\\\\\ t
1: / PLUME
\
. .
I I /.FORMATION
FORMATION
\\\\I |/ / VAPORIZATION
VAPORIZATION
I
\ \iI /
I I /
I I/
\I II
VAPORIZATION RE-RADIATION
RE- RADIATION
RECOIL ATTENUATION
RECOIL FORCE-DEEP PENETRATION
FORCE -DEEP PENETRATION
PLASMA
MULTIPLE REFLECTIONS VAPOR PARTICLES
Fig.
Fig. 3. Laser beam-material
Laser beam -material interactions
interactions Fig. u.
Fig. U. Laser
Laser beam-
beam-material
material interactions
interactions
—
-- Evaporation
Evaporation and
and deep
deep penetration
penetration -- Plume
-- formation and
Plume formation and laser
laser beam
beam
attenuation
attenuation
1.0
0.8
0.6
0.8
0.4
A. polished silver
A, polished silver
B. copper
B. copper
0.2
0.2 C. aluminum
C. aluminum
D. nickel
D. nickel
E. carbon steel
E. carbon steel
o.o;
0.0 iI Iiii I
02
0.2 0.4 0.6 1.0 2 4 8
6 810
8 10 20 Fig. 5.
Fig. 5. The dependence of
The dependence of incident
incident wavelength
wavelength on
on
the reflectivity;
the reflectivity of0 selected
selected materials
materials at
at
room temperature
room temperature''" 2
100
Al
Top — Metals,
Top -- Metals, Bottom
Bottom --
— Various
Various materials
materials
80
Fe
0:
60
4+
V
C
40
SI I
¢ nl
Ii
20
NaCI I
0
0.05 0.1 0.2 0.5
0.5 1
1 22 55 10 20 50
Wavelength, X
X (µm)
G*m)
SPIE
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Chemical Lasers
Lasers (1988)
(1988) // 529
529
w FACE
Ón SION
a v
1.0 10 100
L
POWER, kW
LASER POWER,
HYDROSTATIC PRESSURE
Fig.
Fig. 6,
6. Forces
Forces acting
acting inside
inside the
the keyhole
keyhole Fig.
Fig. 7.
7. The relation between
The relation between penetration
penetration depth
depth and
and
laser power18
laser power
40
LIGHT PATH I
X 30
LIQUID METAL
SURFACE Q.
C
20
LIQUID
10
SOLID METAL
1 2 4 8 12
PULSE
PULSE LENGTH(ms)
LENGTH (ms)
Fig.
Fig. 8.8. Multiple
Multiple reflects reflections in the beam cavity
ns in the beam cavity A Focused
Focused 2.5 mm
2.5 mm below
below the
the metal
metal surface
surface
increase absorption' 9
increase absorption'9 in He
in He
• Focused
Focused at the
at the metal
metal surface
surface in
in He
He
A Focused
O Focused 2.5 mm
2.5 mm below
below the
the metal
metal surface
surface
in
in Ar
Ar
o Focused
o Focused at the
at the metal surface in
metal surface in Ar
Ar
Fig.
Fig. 9.
9. The
The effects of shielding
effects of shielding gas
gas on
on process
process
efficiency of
efficiency of laser
laser spot
spot welding19
welding
SPIE
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Gas Flow
Flow and
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Chemical Lasers
Lasers (1988)
(1988)
2-10 6 -
0.2
jc
i
1-10' O O
0.4 0.8 1.2 1.6 2.0 2.4
Discharge Pulse
Discharge Pulse
Current Length
Length Focus
mA
mA ms
_ 100
1 2 3
0.60
0.60
cO LASER POWER
POWER (kW)
(kW)
0.40
040
o
m
c
0.20
Fig. 11.
Fig. 11. Vaporization
Vaporization and and plasma
plasma threshold
threshold
• If I. t. . I .1. t. . • t. intensities as
intengities as aa function
function of
of input
input laser
laser
power,6
power
0.4 0.8 1.2 1.6
1.6 2.0
2.0 2.4
Thermal conductivity,
conductivity,mw
mw/cm°K (at590
/cm °K (at 590°K)
°K)
Fig. 10.
Fig. 10. The influence of
The influence of thermal
thermal conductivity
conductivity of
of
shielding gas
shielding gas and gas mixtures
and gas mixtures on
on the
the
penetration
penetration depth depth of of laser
laser spot
spot
welding23
welding23 Laser
Laser Beam
Beam
Top --
Top — Pure
Pure gases
gases / Cutting
Cutting Speed
Speed
Bottom --
Bottom — Argon
Argon/Helium
/Helium mixes
mixes
Erosion
Erosion Front
Front
Reactive
Reactive
) Gas Flow
Gas Flow
Molten Layer
Molten Layer
x Solid
Solid Material
Material
1.2 Evaporated
Cross-section
1.0 Material ! Cross- section
of
of the
the workpiece
workpiece
0.8 >x Laser (3.4 kW)
0.6
0.8
0.4
0.2
0.2
1
Reactive
Reactive
/ Ejection of
/ Ejection of
-8 -4 -2 0 4
Gas
Gas Flow
Flow Liquid Material
Liquid Material
WELD CHAMBER
WELD CHAMBERPRESSURE - LOG ,0 (torr)
PRESSURE-LOON (torr)
Fig. 12.
Fig. 12. The influence
The influence of
of ambient
ambient pressure
pressure on
on
penetration depth32
penetration depth3* Fig. 13.
Fig. 13. Gas-assisted
Gas- assisted laser
laser cutting^
cutting35
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