激光−电弧复合焊咬边缺陷研究现状

A review of undercut defects in laser-arc hybrid welding

  • 摘要: 激光−电弧复合焊技术凭借其高效率、高质量的优势在汽车、轨道交通、船舶等领域得到广泛应用,但咬边缺陷严重制约了该技术的进一步推广。该文系统分析了激光−电弧复合焊咬边缺陷的影响因素、形成机理及控制方法。研究表明,咬边缺陷的形成受焊接工艺参数和焊接工况的综合影响,主要包括激光与电弧参数、热源耦合作用、保护气体成分以及母材性质、坡口形式、表面状态等因素。从形成机理角度,咬边缺陷可归因于两种机制,一是熔池受力失衡,表现为熔池受力状态偏离了在熔池凝固时能充分填充焊趾的平衡,形成规律分布的浅宽型咬边;二是熔池动态失稳,源于瞬态扰动(如熔滴冲击、电弧波动、匙孔坍塌)引发的熔池流动波动,导致熔池无法稳定地填充焊趾,形成不规律分布、咬边程度不一致的狭型咬边。在控制方法方面,焊接工艺参数优化和设备改进是当前主要手段,包括热源间距调整、功率比匹配、保护气体优化及摆动激光、外加磁场等技术。尽管已取得显著进展,但多物理场耦合作用的动态响应机制仍需深入研究,未来需构建综合性的咬边缺陷预测模型,为该技术的工业化应用提供理论指导。

     

    Abstract: Laser-arc hybrid welding technology has been widely applied in automotive, rail transportation, and shipbuilding industries due to its high efficiency and superior quality. However, undercut defects significantly limit the further promotion of this technology. This paper systematically analyzes influencing factors, formation mechanisms and control methods of undercut defects in laser-arc hybrid welding. Research indicates that undercut formation is comprehensively influenced by welding parameters and welding conditions, primarily including laser and arc parameters, heat source coupling effects, shielding gas composition, as well as base material properties, groove geometry and surface conditions. From the perspective of formation mechanisms, undercut defects can be attributed to two mechanisms. First is force imbalance in the weld pool, manifested as deviation of the weld pool force state from the equilibrium required for adequate toe filling during solidification, resulting in regularly distributed shallow and wide undercut. Second is dynamic instability of weld pool, originating from transient disturbances (such as droplet impact, arc fluctuation, and keyhole collapse) that induces weld pool flow fluctuations, preventing stable toe filling and leading to irregularly distributed narrow undercut with inconsistent severity. Regarding control methods, welding parameter optimization and equipment improvement are currently the primary approaches, including heat source spacing adjustment, power ratio matching, shielding gas optimization, and techniques such as oscillating laser and external magnetic fields. Despite significant progress, dynamic response mechanisms of multi-physics field coupling still require in-depth investigation. Future research needs to develop comprehensive prediction models for undercut defect to provide theoretical guidance for the industrial application of this technology.

     

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