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高功率激光焊接羽辉能量传输机制及调控方法

Energy transfer mechanism and regulation methods of plasma plume in high-power laser welding

  • 摘要: 激光焊作为现代焊接领域的前沿方向,已在工业中得到广泛应用. 然而,激光焊过程中产生的羽辉会干扰激光能量传输,尤其是在大功率条件下,羽辉对激光能量的吸收会显著增强,导致熔深提升困难并形成功率饱和现象. 本文通过激光与金属材料相互作用机理、焊接羽辉过程监测以及调控方法等方面对现有研究进行总结归纳. 激光焊接过程中,匙孔内部的金属蒸发流动与匙孔外喷发的金属蒸汽共同构成了一个内外能量耦合动态系统. 由于匙孔位于熔池内部,直接观测困难. 当前研究在明确匙孔内部金属蒸发流动的非均匀性的基础上,重点关注匙孔外部喷发的金属蒸汽-等离子体羽辉体系. 通过传感器实时采集羽辉的光、声、电信号,结合多维度表征手段,可建立等离子体动力学与焊接参数的联系,借助计算机神经网络等工具,构建焊接工艺-羽辉动态行为-匙孔稳定之间的映射关系. 调控羽辉的主要手段包括选用脉冲短波长激光器、调控环境介质、改变加工环境压力或气体组分、引入高电离惰性气体等方法. 未来的研究中,应聚焦于明确匙孔内的羽辉对激光能量的影响机制,确立影响匙孔稳定性的羽辉关键特征参量,并开发更高效与灵活性的高密度羽辉抑制装置,以推动大功率激光焊接技术的进一步发展.

     

    Abstract: Laser welding technology, as a forefront of modern welding research, has been widely adopted in industry. However, the plume generated during the laser welding process interferes with the transmission of laser energy, particularly under high-power conditions, where its absorption of laser energy is significantly enhanced. This leads to difficulties in increasing penetration depth and results in power saturation. This paper reviews existing studies from the perspectives of laser-metal interaction mechanisms, monitoring of the welding plume process, and regulation methods. It indicates that during laser welding, the metal vapor flow inside the keyhole and the metal vapor ejected from the keyhole together constitute a dynamically coupled energy system. Direct observation of the keyhole is challenging due to its location within the molten pool. Current research, based on clarifying the non-uniformity of metal vaporization inside the keyhole, primarily focuses on the external metal vapor–plasma plume system ejected from the keyhole. By capturing real-time optical, acoustic, and electrical signals of the plume through sensors and integrating multi-dimensional characterization methods, the relationship between plasma dynamics and welding parameters can be established. Utilizing tools such as computational neural networks enables the construction of mapping relationships among welding parameters, dynamic plume behavior, and keyhole stability. Key approaches for plume regulation include using pulsed short-wavelength lasers, modulating the ambient medium, adjusting processing environmental pressure or gas composition, and introducing highly ionized inert gases. Future research should focus on clarifying the mechanism by which the plume inside the keyhole affects laser energy, identifying key plume characteristic parameters influencing keyhole stability, and developing more efficient and flexible high-density plume suppression devices to advance high-power laser welding technology.

     

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