• Ei tuloksia

CONCLUSIONS AND SUMMARY

The results of this study indicate that by using a 6 kW CO2 laser-MAG hybrid welding process, the welding speed may be increased if an air gap is present in the joint. Experimental trials indicated that the welding speed may be increased by 30-82% when compared with bead-on-plate welding, or welding of a joint with no air gap i.e. a joint prepared as optimum for autogenous laser welding.

It was proofed in this study, that the separation of the different processes, as well as the relative configurations of the processes (arc leading or trailing) also affect welding performance through their influence on droplet size and therefore the metal transfer mode, which in turn determined the resulting weld quality and the ability to bridge air gaps. Welding in the bead-on-plate mode, or of an I butt joint containing no air gap joint is facilitated by using a leading torch, because of the preheating effect of the arc, which increases the absorptivity of the work piece to the laser beam, enabling greater penetration and the use of higher welding speeds. With an air gap present, air gap bridging is more effectively achieved by using a trailing torch because of the lower arc power needed, the wider arc, and the movement of droplets predominantly towards the joint edges.

According to the results of this study, the mode of metal transfer has a marked effect on gap bridgeability. Transfer of a single droplet per arc pulse may not be desirable if an air gap is present, because most of the droplets are directed towards the middle of the joint where no base material is present. In such cases, undercut is observed. Pulsed globular and rotational metal transfer modes enable molten metal to also be transferred to the joint edges, and are therefore superior metal transfer modes when bridging air gaps.

Process separation is also an important factor in gap bridgeability as indicated in this study. If process separation is too large, the resulting weld often exhibits sagging, or no weld may be formed at all as a result of the reduced interaction between the component processes. In contrast, if the processes are too close to one another, the processing region contains excess molten metal that may create difficulties for the keyhole to remain open. When the distance is optimised – i.e. a separation of 0-4 mm in this study, depending on the welding speed and beam-arc configuration – the processes act together, creating beneficial synergistic effects. The optimum process separation when using a trailing torch was found to be shorter (0-2 mm) than when a leading torch is used (2-4 mm);

a result of the facilitation of weld pool motion when the latter configuration is adopted.

The arc process used has a strong effect on the CO2-laser-MAG hybrid welding process. The laser beam welding component is relatively stable and easy to manage, with only two principal processing parameters (power and welding speed) needing to be adjusted. In contrast, the MAG process has been shown to have a major effect on the hybrid process, with a large number of processing parameters to optimise, all of which play an important role in the interaction between the laser beam and the arc. The parameters used for traditional MAG welding are often not optimal in achieving the most appropriate mode of metal transfer, and weld quality in laser hybrid welding, and must be optimised if the full range of benefits provided by hybrid welding are to be realised.

149

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Appendices

Appendix 1: Laser beam analysis of the CO2 laser used in the experiments

Appendix 2: Parameters used in the experiments testing the effect of groove in experiments with welding number 0906xx using low frame rate videographing during welding

Appendix 3: Parameters used in the experiments testing the effect of groove in experiments with welding number 24/2510xx using low frame rate videographing during welding

Appendix 4: Parameters used in the experiments testing the effect of longer distance between the processes on the gap bridgability in experiments with welding number 24/2510xx using low frame rate videographing during welding

Appendix 5: Visual and macrographic examination, quality rating, welding energy and weld cross-sectional area of experiments testing the effect of groove in experiments with welding number 0906xx using low frame rate videographing during welding

Appendix 6: Macrographs of welds made into different grooves with varying welding speeds and torch directions, experiments testing the effect of groove in experiments with welding number 0906xx using low frame rate videographing during welding

Appendix 7: Photographs of the welds made with the highest welding speed to achieve full penetration into different kinds of grooves, experiments testing the effect of groove in experiments with welding number 0906xx using low frame rate videographing during welding

Appendix 8: Visual and macrographic examination, quality rating, welding energy and weld cross-sectional area of experiments testing the effect of groove in experiments with welding number 24/2510xx using low frame rate videographing during welding

Appendix 9: Macrographs of welds made into different grooves with varying welding speeds and torch directions, experiments testing the effect of groove in experiments with welding number 24/2510xx using low frame rate videographing during welding

Appendix 10: Photographs of the welds made with the highest welding speed to achieve full penetration into different kinds of grooves, experiments testing the effect of groove in experiments with welding number 24/2510xx using low frame rate videographing during welding

Appendix 11: Visual and macrographic examination, quality rating, welding energy and weld cross-sectional area of experiments testing the effect of distance between the processes in experiments with welding number 0906xx using low frame rate videographing during welding

Appendix 12: Macrographs of welds made into different grooves with varying welding speeds and torch directions and distances between the processes, experiments testing the effect of distance between the processes in experiments with welding number 0906xx using low frame rate videographing during welding

Appendix 13: Photographs of the welds made with welding speed 1.6 m/min and varying distances between the processes, experiments testing the effect of distance between the processes in experiments with welding number 0906xx using low frame rate videographing during welding

Appendix 14: Visual and macrographic examination, quality rating, welding energy and weld cross-sectional area of experiments testing the effect of 2 and 4 mm distance between the processes into different grooves in experiments with welding number 24/2510xx using low frame rate videographing during welding

Appendix 15: Macrographs of welds made into different grooves with 2 and 4 mm distances between the processes and different filler wire diameters, experiments testing the effect of distance between the processes in experiments with welding number 24/2510xx using low frame rate videographing during welding

Appendix 16: Visual and macrographic examination, quality rating, welding energy and weld cross-sectional area of experiments testing the effect of distance between the processes in experiments with welding number 0102xx using high-speed videographing during welding

Appendix 17: Macrographs of welds made with different distances between the processes, experiments testing the effect of distance between the processes in experiments with welding number 0102xx using high-speed videographing during welding

Appendix 18: Measurements of droplet cross-sections and flight direction observations from high-speed videographs

Appendix 1 Beam analysis with Primes Beam Analyzer of the RS6000 CO2 laser beam with focal length 300 mm:

Weld no Laser power kWAirgapTorch direction Filler wire diameter mm Laser-wire distance mm Welding speed m/min Filler wire feed rate m/minShielding gas composition Shielding gas flow rate l/minSynergy?

Voltage setting V Pulse current A

Pulse time ms

Pulse frequency Hz

Base current ACurrent meanVoltage mean 0906014.7BOPleading0.821.13.450He45Ar5CO225off31.52721.9521638.435.24 0906024.7BOPtrailing0.821.13.450He45Ar5CO225off31.52721.9521638.3235.06 0906034.7BOPleading0.821.23.750He45Ar5CO225off31.52761.9562040.7432.82 0906044.7BOPtrailing0.821.23.750He45Ar5CO225off31.52761.9562039.9432.42 0906054.7BOPleading0.821.44.350He45Ar5CO225off31.72801.9622445.6432.84 0906064.7BOPtrailing0.821.44.350He45Ar5CO225off31.72801.9622446.0733.37 0906074.7BOPleading0.821.6550He45Ar5CO225off322801.9702449.4332.73 0906084.7BOPtrailing0.821.6550He45Ar5CO225off322801.9702449.2532.25 0906094.70leading0.821.6550He45Ar5CO225off322801.9702448.8532.94 0906104.70trailing0.821.6550He45Ar5CO225off322801.9702447.5531.36 090611B4.70leading0.821.44.350He45Ar5CO225off31.72801.9622445.1534.13 0906124.70trailing0.821.44.350He45Ar5CO225off31.72801.9622445.1533.27 0906134.70leading0.821.23.750He45Ar5CO225off31.52761.9562039.7133.74 0906144.70trailing0.821.23.750He45Ar5CO225off31.52761.9562038.7932.41 0906154.70leading0.821.13.450He45Ar5CO225off31.52721.9521635.8135.03 0906164.70trailing0.821.13.450He45Ar5CO225off31.52721.9521636.0635.29 0906174.70.5leading0.821.29.350He45Ar5CO225off32.83001.91184087.3834.23 0906184.70.5trailing0.821.29.350He45Ar5CO225off32.83001.91184087.3135.13 0906194.70.5leading0.821.410.950He45Ar5CO225off333081.913448101.2936.11 0906204.70.5trailing0.821.410.950He45Ar5CO225off333081.91344899.3835.21 0906214.70.5leading0.821.612.450He45Ar5CO225off33.33161.915252113.6736.81 0906224.70.5trailing0.821.612.450He45Ar5CO225off33.33161.915252114.8336.54 0906234.70.5leading0.821.81450He45Ar5CO225off33.83241.91706012537.17 0906244.70.5trailing0.821.81450He45Ar5CO225off33.83241.917060125.436.62 0906254.71leading0.821.624.850He45Ar5CO225off35.8380228484221.2743.73 0906264.71trailing0.821.624.850He45Ar5CO225off35.8380228484223.2543 0906274.71leading0.821.421.450He45Ar5CO225off35.3368224676200.1444.05 0906284.71trailing0.821.421.450He45Ar5CO225off35.3368224676198.4641.58 0906294.70.5leading0.82215.550He45Ar5CO225off343321.918656130.637.13 0906304.70.5trailing0.82215.550He45Ar5CO225off343321.918656127.7836.72 0906314.71.2leading0.821.42550He45Ar5CO225off36380228484227.444.6 0906324.71.2trailing0.821.42550He45Ar5CO225off3638022848422644.15

MAG-parametersRealized values

Appendix 2

Weld no Laser power kWAirgapTorch direction Filler wire diameter mm Laser-wire distance mm Welding speed m/min Filler wire feed rate m/minShielding gas composition Shielding gas flow rate l/minSynergy?Voltage setting V

Pulse current A

Pulse time ms

Pulse frequency Hz

Base current ACurrent meanVoltage mean 241001-V5.20leading1.221.66.450He45Ar5CO225on33.34642.211872171.730.51 241002-T5.20trailing1.221.66.450He45Ar5CO225on33.34642.211872165.1131.74 241004-V5.20.5leading1.222.610.450He45Ar5CO225on364962.2186104235.1728 241005-V5.20.5leading1.222.811.250He45Ar5CO225on36.55042.2200116264.1430.5 241006-T5.20.5trailing1.222.610.450He45Ar5CO225on364962.2186104237.8629.18 241007-T5.20.5trailing1.222.811.250He45Ar5CO225on36.55042.2200116249.2929.93 241008-V5.21leading1.221.612.750He45Ar5CO225on37.55162.2224132314.6734.92 241009-V5.21leading1.221.814.350He45Ar5CO225on38.55282.2252140346.2534.86 241010-V5.21leading1.22215.950He45Ar5CO225on39.55402.227018436035.09 241011-T5.21trailing1.22215.950He45Ar5CO225on39.55402.2270184360.2935.21 241012-T5.21trailing1.222.620.750He45Ar5CO225on42.85802.2270300416.0937.05 241013-T5.21trailing1.222.217.550He45Ar5CO225on40.75562.2270248385.6736.33 241014-V5.21leading1.222.217.550He45Ar5CO225on40.75562.2270248305.535.85 241019-T5.20trailing0.821.614.350He45Ar5CO225on33.8332216852122.6533.91 241020-V5.20leading0.821.614.350He45Ar5CO225on33.8332216852132.6332.7 241021-V5.20leading0.821.816.150He45Ar5CO225on34344218860141.4433.55 241022-T5.20trailing0.821.816.150He45Ar5CO225on34344218860132.7534.08 241023-T5.20.5trailing0.822.421.550He45Ar5CO225on35.3368224872155.1232.97 241024-V5.20.5leading0.822.421.550He45Ar5CO225on35.3368224872168.3333.28 241025-V5.20.5leading0.822.623.350He45Ar5CO225on35.5380226872173.7134.54 241026-T5.20.5trailing0.822.623.350He45Ar5CO225on35.5380226872165.8633.93

MAG-parametersRealized values

Appendix 3

Weld no Laser power kWAirgapTorch direction

Filler wire diameter mm

Laser-wire distance mm Welding speed m/min Filler wire feed rate m/minShielding gas composition Shielding gas flow rate l/minSynergy?

Voltage setting V

Pulse current A

Pulse time ms

Pulse frequency Hz

Base current ACurrent meanVoltage mean 241019-T5.20trailing0.821.614.350He45Ar5CO225on33.8332216852122.6533.91 241020-V5.20leading0.821.614.350He45Ar5CO225on33.8332216852132.6332.7 241003-T5.20trailing1.221.67.950He45Ar5CO225on34.24762.214488201.8932.67 241004-V5.20.5leading1.222.610.450He45Ar5CO225on364962.2186104235.1728 241021-V5.20leading0.821.816.150He45Ar5CO225on34344218860141.4433.55 241022-T5.20trailing0.821.816.150He45Ar5CO225on34344218860132.7534.08 251005-V5.20leading0.841.816.150He45Ar5CO225on34344218860146.833 251006-T5.20trailing0.841.816.150He45Ar5CO225on34344218860133.633.48 241023-T5.20.5trailing0.822.421.550He45Ar5CO225on35.3368224872155.1232.97 241024-V5.20.5leading0.822.421.550He45Ar5CO225on35.3368224872168.3333.28 251001-T5.20.5trailing0.842.421.550He45Ar5CO225on35.3368224872158.6331.72 251002-V5.20.5leading0.842.421.550He45Ar5CO225on35.3368224872170.4333.11 241027-T5.21trailing0.821.62550He45Ar5CO225on36388228480197.8237.26 241028-V5.21leading0.821.62550He45Ar5CO225on36388228480204.5638.69 241029-V5.21leading0.841.62550He45Ar5CO225on36388228480199.0637.29 241030-T5.21trailing0.841.62550He45Ar5CO225on36388228480201.8237.43 241010-V5.21leading1.22215.950He45Ar5CO225on39.55402.227018436035.09 241011-T5.21trailing1.22215.950He45Ar5CO225on39.55402.2270184360.2935.21 241016-V5.21leading1.24215.950He45Ar5CO225on39.55402.2270184358.1535.12 241017-T5.21trailing1.24215.950He45Ar5CO225on39.55402.2270184360.2135.59 241013-T5.21trailing1.222.217.550He45Ar5CO225on40.75562.2270248385.6736.33 241014-V5.21leading1.222.217.550He45Ar5CO225on40.75562.2270248305.535.85 241015-V5.21leading1.242.217.550He45Ar5CO225on40.75562.2270248386.1736.02 241018-T5.21trailing1.242.217.550He45Ar5CO225on40.75562.2270248386.5836.25

Base current ACurrent meanVoltage mean 241019-T5.20trailing0.821.614.350He45Ar5CO225on33.8332216852122.6533.91 241020-V5.20leading0.821.614.350He45Ar5CO225on33.8332216852132.6332.7 241003-T5.20trailing1.221.67.950He45Ar5CO225on34.24762.214488201.8932.67 241004-V5.20.5leading1.222.610.450He45Ar5CO225on364962.2186104235.1728 241021-V5.20leading0.821.816.150He45Ar5CO225on34344218860141.4433.55 241022-T5.20trailing0.821.816.150He45Ar5CO225on34344218860132.7534.08 251005-V5.20leading0.841.816.150He45Ar5CO225on34344218860146.833 251006-T5.20trailing0.841.816.150He45Ar5CO225on34344218860133.633.48 241023-T5.20.5trailing0.822.421.550He45Ar5CO225on35.3368224872155.1232.97 241024-V5.20.5leading0.822.421.550He45Ar5CO225on35.3368224872168.3333.28 251001-T5.20.5trailing0.842.421.550He45Ar5CO225on35.3368224872158.6331.72 251002-V5.20.5leading0.842.421.550He45Ar5CO225on35.3368224872170.4333.11 241027-T5.21trailing0.821.62550He45Ar5CO225on36388228480197.8237.26 241028-V5.21leading0.821.62550He45Ar5CO225on36388228480204.5638.69 241029-V5.21leading0.841.62550He45Ar5CO225on36388228480199.0637.29 241030-T5.21trailing0.841.62550He45Ar5CO225on36388228480201.8237.43 241010-V5.21leading1.22215.950He45Ar5CO225on39.55402.227018436035.09 241011-T5.21trailing1.22215.950He45Ar5CO225on39.55402.2270184360.2935.21 241016-V5.21leading1.24215.950He45Ar5CO225on39.55402.2270184358.1535.12 241017-T5.21trailing1.24215.950He45Ar5CO225on39.55402.2270184360.2135.59 241013-T5.21trailing1.222.217.550He45Ar5CO225on40.75562.2270248385.6736.33 241014-V5.21leading1.222.217.550He45Ar5CO225on40.75562.2270248305.535.85 241015-V5.21leading1.242.217.550He45Ar5CO225on40.75562.2270248386.1736.02 241018-T5.21trailing1.242.217.550He45Ar5CO225on40.75562.2270248386.5836.25