Abstract:
In narrow gap laser–arc hybrid welding, droplet transfer behavior indirectly affects the formation of porosity defects by influencing molten pool disturbance and keyhole stability. To reveal the correspondence between droplet transfer and porosity under different process conditions, a comparative analysis was conducted on droplet transfer characteristics and weld porosity distribution with variations in laser power, wire feeding speed, and welding speed. The results show that the droplet transfer mode has a significant correlation with porosity. Under the parameter combination of a laser power of 3.2 kW, a welding speed of 0.96 m/min, and a wire feeding speed of 9 m/min, the porosity reaches the minimum value of approximately 0.34%.When the laser power increases to 4.2 kW, the droplet transfer transforms into a short-circuiting transfer mode, the welding process fluctuations increase, and the porosity significantly rises. The effect of wire feeding speed on porosity shows a trend of first decreasing and then increasing; at a lower wire feeding speed, the arc stiffness is insufficient, whereas at a higher wire feeding speed, droplet impact is enhanced and molten pool disturbance is intensified. When the welding speed deviates from an appropriate range, arc deflection is induced, causing droplets to fall with an offset and altering local molten pool flow, thereby increasing the porosity.