Hybrid Laser Arc Welding

By:
Krystina petelova
Febi luthfiani
Vinda puspasari
 Outline
History (vinda)
Description
Types
Characterization
Process (krystina)
Paramaters
Joint Designs
Defects (febi and krystina)
Application
Advantages
Limitations (febi)
 History
1970s as arc-augmented laser
welding that combined LBW
with gas tungsten arc welding
(GTAW) (Ref 1).
arc processes including GTAW,
gas metal arc welding (GMAW),
and plasma arc welding have
been used;
GMAW has become the most
popular arc process for HLAW
high-power continuous-wave
lasers such as carbon dioxide
(CO2) gas lasers and solid-
state neodymium-doped
yttrium-aluminum-garnet
(Nd:YAG) lasers have been
used for HLAW
 Description
Hybrid welding combines laser beam welding and arc welding
to provide advantages not found in either. This method get
advantage from both methodes.

This method has two variation of welding direction

http://www.twi-global.com/capabilities/joining-technologies/lasers/hybrid-laser-arc-weldin
g/
http://www.slideshare.net/OmerChasib/laser-arc-hybrid-welding
Description (2)
 Types of hybrid laser arc
welding
(:YAG,
According to the source of laser beam:
diode, Yb, fibre, Yb:YAG disk)

According to the heating source:

1. Laser-gas tungsten arc welding (GTA)
2. Laser-gas metal arc welding (GMA)
3. Laser-plasma welding
http://www.slideshare.net/OmerChasib/laser-arc-hybrid-welding
 Jelasin macam2 Laser beam
For most structural metals 1kW of
laser power is needed to provide 1
mm of penetration under the speed
of 2m/min
For low carbon steel 10kW with
2,3m/min can provide full
penetration of 9,5 mm square butt
joint
http://www.twi-
global.com/capabilities/joining-
technologies/lasers/hybrid-laser-arc-
Laser-gas tungsten arc welding (GTA)

In GTA welding, a chemically inert gas, such as argon or

helium, is often used.
Laser-gas metal arc welding (GMA)
Laser-plasma welding
Characterization of welding
Low distortion in joint compared to MAW or
SAW
=>lower cost of reworking and correction of
weld (20-30%)
High welding speed ( 5m/min, steel and
alluminum up to 14m/min )
Improved weld quality:
Hot cracking can be avoided (in some higher
strenght Al alloys)
Internal porosity content reduced
 Parameters
1. Distance between laser focal point and impingement of the
arc
2. Geometrical formation of laser beam and arc torch
3. Shielding gas
4. Travel Speed
5. Process Orientation
6. GMAW Current, Voltage and Polarity
7. Wire Feed Speed
 Joint
-Deep penetration welds comparable
with laser welds
Controlled by choice of laser and
parameters.
Penetration up to 6-12mm possible
with high power laser
Ytterbium-fiber penetration up to
28 mm

-Tolerance to joint fit-up and a weld

cap profile comparable with arc welds.

-Gasses to protect the pool can be

used

- Many types of joint desing can be

gle-group.eu
welded as ( butt, grove, lap, flange,
ww.twi-global.com/capabilities/joining-technologies/lasers/hybrid-laser-arc-welding/
ww.asminternational.org/documents/10192/22533690/05264G_Sample_BuyNow.pdf/12bdd4e6-d526-4c5d-9a99-ba10c370e86f
fillet, different depth up to 2 mm)
 Defects
Undercut and concavity
-due to gap, which can not
be filled by the deposited
wire, undercut can occur
due to high travel speed
Incomplete fusion-
Undercut and concavity
deviation in narrow weld
profiles
Incomplete penetration
 Root humping defect
Root humping- longitudinal humping profile at the
back of the joint, mostly in steel, physical
phenomena causing this is not fully understood,
increasing power stabilizes full penetration
keyhole and eliminates humping

app.aws.org
 Solves
Reducing the welding speed
Increasing the wire feed rate and/or
arc voltage trim
Changing the stand-off height of the
welding head
Deliberataly off setting the laser
beam off of the joint line (by off-
setting the welding head)
Laser Beam - GMAW
 Advantages :
Gas Metal Arc
Laser Welding Welding (GMAW) /
MIG
1. Good quality : Narrow, deep 1. Excellent gap
weld seam bridging ability
2. High Completion rates 2. Low cost of
3. Low consumable costs (no equipment
filler required) 3. High efficiency of
4. Low but concentrated heat the process (60-
input, which result in low and 80%)
predictable distortion levels
5. Reduce post weld rework
6. No mechanical contact
between the laser eqipment
and the workpieces
7. Joining of widely dissimilar
 Drawbacks :
Gas Metal Arc Welding
Laser Welding (GMAW) / MIG
1. High cost of equipment 1. Energy density and
and maintenance welding speed lower
2. Poor gap bridging compared to laser
ability welding
3. Limited welding 2. Low speed
positions
4. Poor electrical
efficiency (2% for CO2
lasers, 10% for Nd:YAG
lasers)
5. Occasional
metallurgical problems
due to the high cooling
Hybrid Laser Arc Welding
(HLAW)
 Advantages of HLAW
Lower capital cost, reduction of 30-40%
Higher welding speeds
Reduction of edge preparation accuracy needs
Control of seam width
Control of metallurgical variables through the
addition of filler wire
Less material hardening
Improved process reliability
Higher electrical efficiency, up to 50% in
power consumption
 Limitations of HLAW
Precise alignment and strict part fit-up are required to
maintain weld consistency and quality with HLAW
Hybrid laser arc welding is only used in mechanized or
automated applications
Because of the small focal spot diameter of the laser beam,
thick-section butt joints with a gap exceeding 1 mm (0.039
in.) are difficult to weld
HLAW (the low heat input and fast cooling rates), mechanical
properties of the as-welded condition may ,be poorer than MP
from arc welding process with higher heat inputs
Due to the expensive laser equipment, capital cost for HLAW
systems can be 10 to 50 times higher than GMAW systems
additional safety measures are necessary with HLAW to
protect personnel from laser hazards
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 Applications of HLAW
Automotive Volkswagen and Audi Lasers from 24 kW
Welding Speed 4m/min
MAYER in Germany Lasers > 6 kW for
Shipbuilding KVAERNER in Finland Nd:YAG
FINCANTIERI in Italy Lasers > 25 kW for CO2
lasers
Pipe lines and Improve weld quality and Welding speed > 1.2
offshore reduce manufacturing costs of m/min for a wall
installations pipe lines thickness of 5-8 mm
Aerospace High quality welds in thin
and aviation titanium alloys with very good
industry results
Power Applied in a multiple pass Thick plates of over 15
generation mode mm
Off road and Domestic appliances, railways
heavy vehicle and chemical (the joining of
tanks and tubes designed for
chemical
plants, often made of stainless
steel)
 Conclusions
HLAW has gained significant industrial attention
Various joint configurations can be hybrid welded at
high speed
The displacement between the laser beam and the
arc modifies the weld pool shape
During hybrid welding the melt pool is significantly
enlarged, permitting more extensive melt flow
Energy transfer is the result of the electrode current,
shielding gas convention and laser beam absorption
the weld seam shape is governed by the wire
feeding rate relative to welding speed and gap
width