This document discusses laser beam welding. It begins by defining what a laser is and how it is used for welding. It then covers the physics behind how lasers work, including how they are generated and amplified. The document discusses different types of lasers, including solid-state Nd:YAG lasers, gaseous CO2 lasers, direct-diode lasers, and fiber lasers. It notes the advantages and limitations of laser beam welding and covers applications of different laser types.
This document discusses laser beam welding. It begins by defining what a laser is and how it is used for welding. It then covers the physics behind how lasers work, including how they are generated and amplified. The document discusses different types of lasers, including solid-state Nd:YAG lasers, gaseous CO2 lasers, direct-diode lasers, and fiber lasers. It notes the advantages and limitations of laser beam welding and covers applications of different laser types.
This document discusses laser beam welding. It begins by defining what a laser is and how it is used for welding. It then covers the physics behind how lasers work, including how they are generated and amplified. The document discusses different types of lasers, including solid-state Nd:YAG lasers, gaseous CO2 lasers, direct-diode lasers, and fiber lasers. It notes the advantages and limitations of laser beam welding and covers applications of different laser types.
Introduction • LASER – Light Amplification by Stimulated Emission of Radiation • A coherent, monochromatic electromagnetic radiation. • Heat from the concentrated LASER beam is impinged on the metal joint and a fusion weld is obtained. • No vacuum is required. • An inert atmosphere is generally provided to avoid contamination. • Less power than EBW. • Maximum of 19 mm penetration in single pass welding. Physics of Laser • It can propagate over large distances without much divergence. • It has a very narrow bandwidth • Emission may be continuous or short or ultra-short pulses. LASER GENERATION • A crystal or medium is stimulated by “pumping” using external energy • External Energy may be electrical, chemical, thermal, optical or nuclear. • The medium gets energized – “Population Inversion” occurs. • Atoms or molecules in the medium are in a higher than normal energy state. • These higher energy state produces coherent beams of light, when moving back to lower energy states. • This light is oscillated between two mirrors kept at the 2 ends of the medium. • Each oscillation results in some GAIN of beam power as well as some LOSSES. • When the GAIN is larger than the LOSSES, it is said to have achieved LASER THRESHOLD. • Once threshold is achieved the device starts emitting some portion of the beam through the output coupler. • LASER light can be focused on to a small point either using lenses or mirrors. • LASERs are used for welding, cutting, etching etc. ADVANTAGES 1. Heat Input is the amount minimum required to fuse the weld metal. 2. Distortion and heat related issues in the HAZ are minimized. 3. No need of conducting electrodes. 4. No tool wear as LBW is a non-contact welding process 5. Readily focused, aligned and directed by optical elements to weld otherwise inaccessible areas 6. Can be focused on a very small area, permitting joining of closely spaced small components with small welds 7. A wide variety of materials and combinations can be welded easily. 8. Can be automated with CNC machines 9. No vacuum needed and no X-rays are generated 10. Aspect ratios of 10:1 are attainable by keyhole LBW LIMITATIONS 1. Joints must be accurately positioned and at a controlled position with respect to Laser beam focal spot 2. Maximum joint thickness is limited to 19 mm. 3. High reflectivity and high thermal conductivity of materials will adversely affect the weldability 4. Low energy conversion efficiency 5. Due to rapid cooling of weldment, brittleness and porosity can occur in the weld. 6. LASER equipment and fixturing cost may be high. Types of LASERs • Based on the lasing medium used 1. Solid-state (Nd:YAG LASERs) 2. Gaseous (CO2 Lasers) 3. Direct-diode Lasers 4. Fiber Lasers Nd:YAG (Solid State) • Neodimium ion, Nd(+++) ion is used as an active medium. • It is doped to a host – Glass or YAG Crystal. • 1.06µm wavelength laser is characteristic of Nd:YAG • Crystal is excited by using an intense krypton or xenon lamp or using diode lasers(in recent designs). • 2 modes – Pulsed Laser or Continuous Laser. • Pulsed Laser – Pulse width of 25 milliseconds maximum. • Continuous Laser – greater than 25 milliseconds. • Using multiple laser rods can give us power levels greater than 1 kW. • Continuous wave (CW) Nd:YAG are second only to CW gas lasers in terms of power generation. • Lamp pumped Nd:YAG are of less efficiency (2%). • Diode pumped Nd:YAG lasers have 30% efficiency. • Pulsed Wave Lasers have pulsed pumping. GAS Lasers • Electric discharge CO2 lasers are most efficient for welding applications. • 3 parts – Optical cavity, Gas Flow Loop, Electric Discharge System. • Gas mixture of primarily Nitrogen, Helium and small percentage of CO2. • Common – (15:80:5) • “Electric Glow” discharge is used to excite CO2 molecules. • Gas heating is produced by continuous flow of gas mixture through optical cavity. • Classified as per the type of gas flow syste, • Slow axial, Fast axial, Transverse or Diffusion cooled designs Slow Axial Flow Fast Axial Diffusion Cooled Transverse Flow Direct-diode Lasers • Similar to LED, but coherent and monochromatic with higher power. • High electrical conversion efficiency. • Extremely compact. • Limitation of asymmetrical focal spots and power densities. • Key hole mode not possible, only conduction mode possible. Fiber Lasers • Obtained from telecommunication field. • Uses diodes to generate the LASER and glass fibers to transmit the beam. • Generation also done in the fiber. • High quality. Ability to focus to a minute point.