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Journal ArticleDOI

Review of laser hybrid welding

09 Feb 2005-Journal of Laser Applications (Laser Institute of America)-Vol. 17, Iss: 1, pp 2-14
TL;DR: In this paper, an overview of the hybrid welding process is given, including reports on gap bridging ability, changes in welding speed and weld penetration, overall weld quality, and changes in heat input to the material being welded.
Abstract: In this article, an overview of the hybrid welding process is given. After a short historic overview, a review of the fundamental phenomenon taking place when a laser (CO2 or Nd:YAG) interacts in the same molten pool as a more conventional source of energy, e.g. tungsten in-active gas, plasma, or metal inactive gas/metal active gas. This is followed by reports of how the many process parameters governing the hybrid welding process can be set and how the choice of secondary energy source, shielding gas, etc. can affect the overall welding process. An overview of the benefits and drawbacks of hybrid welding is presented, including reports on gap bridging ability, changes in welding speed and weld penetration, overall weld quality, and changes in heat input to the material being welded. This overview is followed by a few examples of industrial applications of hybrid welding. Finally, a section is devoted to explain about further work required in order to understand and tackle the hybrid welding process more efficiently in the future.In this article, an overview of the hybrid welding process is given. After a short historic overview, a review of the fundamental phenomenon taking place when a laser (CO2 or Nd:YAG) interacts in the same molten pool as a more conventional source of energy, e.g. tungsten in-active gas, plasma, or metal inactive gas/metal active gas. This is followed by reports of how the many process parameters governing the hybrid welding process can be set and how the choice of secondary energy source, shielding gas, etc. can affect the overall welding process. An overview of the benefits and drawbacks of hybrid welding is presented, including reports on gap bridging ability, changes in welding speed and weld penetration, overall weld quality, and changes in heat input to the material being welded. This overview is followed by a few examples of industrial applications of hybrid welding. Finally, a section is devoted to explain about further work required in order to understand and tackle the hybrid welding process more ...
Citations
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Book
12 Mar 2014
TL;DR: In this paper, the effect of reflectivity of the surface, when a pure, monochromatic laser (6) is used, is remedied by the simultaneous application of a relatively shorter wavelength beam (1).
Abstract: In the laser treatment of a workpiece (9), e.g. for surface hardening, melting, alloying, cladding, welding or cutting, the adverse effect of reflectivity of the surface, when a pure, monochromatic laser (6) is used, is remedied by the simultaneous application of a relatively shorter wavelength beam (1). The two beams (1)(5) may be combined by a beam coupler (4) or may reach the workpiece (9) by separate optical paths (not shown). The shorter wavelength beam (1) improves the coupling efficiency of the higher- powered laser beam (5).

1,539 citations

Journal ArticleDOI
TL;DR: Hybrid welding as mentioned in this paper combines the combination of a laser and an electrical arc to overcome problems commonly encountered during either laser or arc welding such as cracking, brittle phase formation and porosity.
Abstract: Hybrid welding, using the combination of a laser and an electrical arc, is designed to overcome problems commonly encountered during either laser or arc welding such as cracking, brittle phase formation and porosity. When placed in close contact with each other, the two heat sources interact in such a way as to produce a single high intensity energy source. This synergistic interaction of the two heat sources has been shown to alleviate problems commonly encountered in each individual welding process. Hybrid welding allows increased gap tolerances, as compared to laser welding, while retaining the high weld speed and penetration necessary for the efficient welding of thicker workpieces. A number of simultaneously occurring physical processes have been identified as contributing to these unique properties obtained during hybrid welding. However, the physical understanding of these interactions is still evolving. This review critically analyses the recent advances in the fundamental understa...

193 citations

Journal ArticleDOI
TL;DR: In this paper, a hybrid fiber laser arc welding system was successfully applied to fully penetrate 9.3mm thick butt joints using a single-pass process through optimization of the groove shape, size and processing parameters.

143 citations

Journal ArticleDOI
TL;DR: The synergic effects of laser beam and eclectic arc in the same weld pool results in an increase of welding speed and penetration depth along with the enhancement of gap bridging capability and process stability.
Abstract: Hybrid laser arc welding simultaneously utilizes the arc welding and the laser welding, in a common interaction zone. The synergic effects of laser beam and eclectic arc in the same weld pool results in an increase of welding speed and penetration depth along with the enhancement of gap bridging capability and process stability. This paper presents the current status of this hybrid technique in terms of research, developments and applications. Effort is made to present a comprehensive technical know-how about this process through a systematic review of research articles, industrial catalogues, technical notes, etc. In the introductory part of the review, an overview of the hybrid laser arc welding is presented, including operation principle, process requirements, historical developments, benefits and drawbacks of the process. This is followed by a detailed discussion on control parameters those govern the performance of hybrid laser arc welding process. Thereafter, a report of improvements of performance and weld qualities achieved by using hybrid welding process is presented based on review of several research papers. The succeeding sections furnish the examples of industrial applications and the concluding remarks.

123 citations

Journal ArticleDOI
TL;DR: In this article, the authors define hybrid laser welding technologies as the combination of a high quality laser heat source with an additional secondary heat source, and classify known hybrid techniques by the type of the heat sources used as well as their arrangement relative to each other.
Abstract: Hybrid laser welding technologies can be defined as the combination of a high quality laser heat source with an additional secondary heat source. Based on such a definition, known hybrid techniques are classified by the type of the heat sources used as well as their arrangement relative to each other. The classification is followed by a discussion of different theoretical aspects occuring during a hybrid laser beam welding process concerning the plasma characteristics and the resultant temperature distribution of the superposed heat sources. Finally, some practical examples demonstrate how the potential of hybrid technologies can be used to extend the application spectrum of the laser beam welding process.

121 citations

References
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Dissertation
01 Jan 1979

119 citations

Proceedings ArticleDOI
03 Mar 2003
TL;DR: In this paper, the effects of many process parameters such as welding current, arc voltage, welding speed, defocusing distance, laser-to-arc distance on penetration depth, bead shape, spatter, arc stability and plasma formation were investigated.
Abstract: Researches and developments of laser and arc hybrid welding has been curried out since in 1978. Especially, CO 2 laser and TIG hybrid welding has been studied for increasing the penetration depth and welding speed. Recently laser and MIG/MAG/Plasma hybrid welding processes have been developed and applied to industries. It was recognized as a new welding process that promote the flexibility of the process for increasing the penetration depth, welding speed and allowable joint gap and improving the quality of the welds. In the present work, CO 2 Laser-MAG hybrid welding of carbon steel (SM490) was investigated to make clear the phenomenon and characteristics of hybrid welding process comparing with laser welding and MAG process. The effects of many process parameters such as welding current, arc voltage, welding speed, defocusing distance, laser-to-arc distance on penetration depth, bead shape, spatter, arc stability and plasma formation were investigated in the present work. Especially, the interaction of laser plasma and MAG arc plasma was considered by changing the laser to arc distance (=D LA ).

58 citations

Proceedings ArticleDOI
01 Jan 1994
TL;DR: In this article, the authors describe the plasma phenomena and how it is possible to combine arc and laser beam welding in an optimal way, on the one hand the welding speed could be increased and on the other hand the same welding depths could be reached with a reduced laser power.
Abstract: In the case of welding with CO2-laser the overall efficiency will be between 2% and 5%. Using a Nd:YAG-laser the efficiency is only between 1% and 2%. Compared to that, metal arc welding has a very high efficiency and the arc welding machine has a more than 10 times lower price than a laser system. Besides several distinctions concerning process and welding results laser beam and arc metal welding are characterized by different geometries of the melt pool. In the case of arc metal welding the weld seam is defined by a lower ratio of seam depths to widths. In laser welding this ratio is quite high. These distinctions are influencing e. g. geometrical tolerance requirements, gaps bridging ability or the heat input which is necessary to solve the defined welding problem.Both welding processes are governed by plasma phenomena. The paper describes the plasma phenomena and how it is possible to combine both processes to reach a higher efficiency. By combing arc and laser beam welding in an optimal way, on the one hand the welding speed could be increased and on the other hand the same welding depths could be reached with a reduced laser power.In overlap welding as well as in case of gaps the combination allows to get a bigger seam width and that means a bigger gap between the workpieces could be excepted. Welding results on steel sheets in overlap and butt joints are discussed with regard to process parameter for CO2- and Nd:YAG-laser welding combined with the arc metal welding process.In the case of welding with CO2-laser the overall efficiency will be between 2% and 5%. Using a Nd:YAG-laser the efficiency is only between 1% and 2%. Compared to that, metal arc welding has a very high efficiency and the arc welding machine has a more than 10 times lower price than a laser system. Besides several distinctions concerning process and welding results laser beam and arc metal welding are characterized by different geometries of the melt pool. In the case of arc metal welding the weld seam is defined by a lower ratio of seam depths to widths. In laser welding this ratio is quite high. These distinctions are influencing e. g. geometrical tolerance requirements, gaps bridging ability or the heat input which is necessary to solve the defined welding problem.Both welding processes are governed by plasma phenomena. The paper describes the plasma phenomena and how it is possible to combine both processes to reach a higher efficiency. By combing arc and laser beam welding in an optimal way, on the o...

38 citations