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TC4钛合金摆动激光填丝焊接工艺对焊缝成形的影响及机理分析

Study on the influence and mechanism of oscillating laser wire feed welding process on the weld formation of TC4 titanium alloy

  • 摘要: 为探究钛合金摆动激光填丝焊对焊缝成形的影响规律及其机理,于TC4板材表面进行堆焊试验,并通过高速摄像观测焊接过程. 结果表明,较常规激光,摆动激光在较大工艺窗口内对焊缝成形有明显改善作用,送丝速度、摆动幅度和摆动频率均可显著影响焊缝横截面特征参量. 根据高速摄像采集图像发现,常规激光条件下,熔滴倾向于大滴过渡,当激光摆动幅度为1 mm时,在摆动频率为80 Hz或160 Hz条件下熔滴以稳定的液桥过渡;当摆动幅度为2 mm时,熔滴以固-液混合颗粒过渡. 分析认为,常规激光对焊丝的持续作用增大了熔滴的大滴过渡倾向,造成熔池剧烈波动,焊缝成形不均匀;摆动激光可搅动熔池,促进熔池与焊丝接触形成液桥,焊缝成形良好,但当摆动幅度过大时,激光无法快速熔化焊丝,焊丝从中部折断形成的固-液混合颗粒过渡至熔池后难以充分熔化铺展,造成焊缝锯齿形边缘.

     

    Abstract: In order to investigate the influence and mechanism of oscillating laser on weld formation in titanium alloy laser wire feed welding, resurfacing welding experiments on TC4 plates are conducted, and the welding process is observed using high-speed camera. The results demonstrate, compared with conventional laser welding, oscillating laser welding demonstrates significant enhancement in weld bead morphology within an expanded process window. where wire feeding speed, oscillation amplitude, and oscillation frequency are identified as critical parameters exerting substantial influences on cross-sectional characteristic dimensions. Besides the wire feed speed, oscillation amplitude, and oscillation frequency significantly influence the weld forming characteristic parameters. High-speed imaging reveals that under conventional laser conditions, molten droplets predominantly exhibit large droplet transition. When the oscillation amplitude of laser is set to 1 mm, stable liquid bridge transition is achieved at both 80 Hz and 160 Hz oscillation frequencies. However, with an increased oscillation amplitude of 2 mm, the droplet transition shifts to a solid-liquid mixing particle transition. Analysis reveals that sustained laser irradiation in conventional welding processes increases the propensity for large droplet transition from the wire, resulting in violent molten pool fluctuations and irregular weld bead formation. In contrast, oscillating laser actively stirs the molten pool, enhancing wire-pool interfacial contact to facilitate stable liquid bridge transition and achieve uniform weld morphology. However, when the oscillation amplitude reaches 2 mm, insufficient laser energy density fails to completely melt the wire causing the wire fracturing in the middle that generates solid-liquid mixing particles. These particles exhibit incomplete melting and spreading in the molten pool, ultimately leading to serrated weld edges.

     

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