A Comprehensive Technical Guide to Laser Beam Welding of Stainless Steels

Konjiniyela, abakhi, nabaphathi bemisebenzi, inselele ayiguquki: indlela yokujoyina izingxenye zensimbi engagqwali ngaphandle kokuguquguquka, ukuguquguquka kombala, nokunciphisa ukumelana nokugqwala okukhungethe izindlela ezijwayelekile. Isixazululo siwukuthilaser Welding insimbi engagqwali, ubuchwepheshe obushintshayo obuletha isivinini esingenakuqhathaniswa, ukunemba, kanye nekhwalithi leyo i-TIG evamile ne-MIG yokushisela engakwazi ukufana nayo.

Ukushisela nge-laser kusebenzisa i-beam yokukhanya egxile kakhulu ukuze incibilike futhi ifake insimbi engagqwali ngokufakwa okuncane kokushisa okulawulwayo. Le nqubo eshayelwa ukunemba ixazulula ngokuqondile izinkinga eziyinhloko zokuhlanekezela ukushisa kanye nevolumu yokushisela.

Izinzuzo ezibalulekile ze-Laser Welding Stainless Steel:

• Isivinini Esingavamile:Isebenza ngokushesha izikhathi ezi-4 kuye kweziyi-10 kune-TIG yokushisela, ikhulisa kakhulu ukukhiqiza kanye nokuphumayo.

• Ukuhlanekezela Okuncane:Ukushisa okugxilisiwe kudala indawo encane kakhulu Ethinteke Ukushisa (HAZ), enciphisa kakhulu noma eqeda ukungqubuzana, okugcina ukunemba kobukhulu bengxenye.

• Ikhwalithi Ephakeme:Ikhiqiza amashisela ahlanzekile, aqinile, futhi ajabulisa ngobuhle adinga kancane noma angabikho ukugaywa noma ukuqedwa.

• Izinto ezibonakalayo Ezilondoloziwe:Okokufaka kokushisa okuphansi kugcina amandla ensimbi engagqwali engokwemvelo kanye nokumelana nokugqwala okubalulekile, kuvimbele izinkinga ezifana nokuthi "i-weld decay".

Lo mhlahlandlela uhlinzeka ngolwazi lochwepheshe oludingekayo ukuze usuke ekuqondeni okuyisisekelo uye ekusetshenzisweni okuzethembayo, uqinisekisa ukuthi ungasebenzisa amandla aphelele ale ndlela yokukhiqiza ethuthukisiwe.

I-Laser Weldingvs. Izindlela Zendabuko: Ukuqhathanisa Ikhanda nekhanda

Ukukhetha inqubo yokushisela efanele kubalulekile ukuze iphrojekthi iphumelele. Nansi indlela i-laser welding enqwabelana ngayo ngokumelene ne-TIG ne-MIG ekusetshenzisweni kwensimbi engagqwali.

I-Laser Welding vs. TIG Welding

Ukushisela kwe-Tungsten Inert Gas (TIG) kwaziwa ngezinga eliphezulu, ukushisela okwenziwa ngesandla kodwa kuyazabalaza ukuhambisana nesivinini endaweni yokukhiqiza.

• Isivinini nokukhiqiza:Ukushisela nge-laser kuyashesha kakhulu, okwenza kube yisinqumo esicacile sokukhiqiza okuzenzakalelayo kanye nevolumu ephezulu.

• Ukushisa nokuhlanekezela:I-TIG arc iwumthombo wokushisa ongasebenzi kahle, osakazayo odala i-HAZ enkulu, okuholela ekuhlanekeni okukhulu, ikakhulukazi eshidini lensimbi elincanyana. I-laser's focused beam ivimbela lokhu konakala kokushisa okusabalele.

• Okuzenzakalelayo:Amasistimu e-laser alula ngokwemvelo ukuwenza ngokuzenzakalelayo, anike amandla ukukhiqizwa kwevolumu ephezulu, okuphindaphindwayo okunekhono elincane lezandla elidingekayo kune-TIG.

I-Laser Welding vs. I-MIG Welding

I-Metal Inert Gas (MIG) yokushisela iyinqubo eguquguqukayo, ene-deposition ephezulu, kodwa ayinakho ukunemba kwelaser.

• Ukunemba Nekhwalithi:Ukushisela nge-laser kuyinqubo engathinteki ekhiqiza amashisela ahlanzekile, angenawo ama-spatter. Ukushisela kwe-MIG kujwayele ukuba ne-spatter edinga ukuhlanzwa ngemuva kokushisela.

• Ukubekezelela Igebe:Ukushisela kwe-MIG kuthethelela kakhulu ukulingana okungalungile kwamalunga ngoba intambo yayo esebenzisekayo isebenza njengesigcwalisi. I-laser welding idinga ukulungiswa okuqondile nokubekezelelana okuqinile.

• Ubukhulu Bezinto:Ngenkathi ama-laser anamandla amakhulu ekwazi ukuphatha izingxenye eziwugqinsi, i-MIG ivamise ukuthi isebenziseke kakhulu kupuleti elisinda kakhulu. I-laser welding idlula ugqinsi oluncane ukuya kolumaphakathi lapho ukulawulwa kokuhlanekezela kubalulekile.

At-a-Glance Comparison Table

Isayensi Behind the Weld: Izimiso Eziyinhloko Zichazwe

Ukuqonda ukuthi i-laser isebenzisana kanjani nensimbi engagqwali kuyisihluthulelo sokwazi inqubo. Isebenza ngokuyinhloko ngezindlela ezimbili ezihlukene ezinqunywe ukuminyana kwamandla.

I-Conduction Mode vs. Keyhole Mode

• I-Conduction Welding:Emazingeni aphansi wamandla, i-laser ishisa ingaphezulu lezinto ezibonakalayo, futhi ukushisa “kudlulela” engxenyeni. Lokhu kudala i-weld engashoni, ebanzi, futhi ebushelelezi ngobuhle, elungele izinto ezincane (ngaphansi kuka-1-2 mm) noma imithungo ebonakalayo lapho ukubukeka kubaluleke kakhulu.

• I-Keyhole (Ukungena Okujulile) Ukushisela:Emazingeni aphakeme kagesi (cishe u-1.5 MW/cm²), i-laser ihwamulisa insimbi ngokushesha, idale indawo ejulile, encane ebizwa ngokuthi “imbobo yokhiye.” Le mbobo kakhiye ivalela amandla e-laser, iwahambise ekujuleni kokubalulekile ukuze uthole amashisela aqinile, angena ngokugcwele ezigabeni eziwugqinsi.

I-Continuous Wave (CW) vs. Pulsed Lasers

• I-Continuous Wave (CW):I-laser iletha umsebe wamandla ongapheli, ongaphazamiseki. Le modi ilungele ukudala ama-seam amade, aqhubekayo ngesivinini esikhulu ekukhiqizeni okuzenzakalelayo.

• I-Pulsed Laser:I-laser iletha amandla ngamafuphi amafushane, ukuqhuma okunamandla. Le ndlela ihlinzeka ngokunemba kokulawula okokufaka ukushisa, inciphisa i-HAZ futhi iyenze ilungele ukushisela izinto ezithambile, ezingezwani nokushisa noma ukudala amashisela agqagqene ukuze avale kahle.

Isinyathelo Ngesinyathelo Umhlahlandlela Wokulungiselela Okungenasici

Ekushiseleni nge-laser, impumelelo inqunywa ngaphambi kokuba ugongolo lusebenze. Ukunemba kwenqubo kudinga ukulungiswa ngokucophelela.

Isinyathelo 1: Idizayini Ehlanganyelwe kanye ne-Fit-Up

Ngokungafani ne-arc welding, i-laser welding inokubekezelela okuphansi kakhulu kwezikhala noma ukungahambi kahle.

• Izinhlobo Ezihlangene:Amajoyinti ezinqe yiwona asebenza kahle kakhulu kodwa adinga igebe elicishe libe uziro (ngokuvamile lingaphansi kuka-0.1 mm ezigabeni ezincane). Ama-Lap joints athethelela kakhulu ukuhlukahluka kokulingana.

• Ukulawula Igebe:Igebe eliningi lizovimbela ichibi elincane elincibilikisiwe ukuthi livale ilunga, okuholela ekuhlanganiseni okungaphelele kanye nokushisela okubuthakathaka. Sebenzisa izindlela zokusika ezinembayo kanye nokubamba okuqinile ukuze uqinisekise ukuqondanisa okuphelele.

Isinyathelo sesi-2: Ukuhlanza ubuso kanye nokususwa kokungcola

Amandla amakhulu e-laser azohwamuka noma yikuphi ukungcola okungaphezulu, akuvalele endaweni eshiselayo futhi kubangele amaphutha afana ne-porosity.

• Inhlanzeko Ibalulekile:Indawo engaphezulu kufanele ingabi nawo ngokuphelele amafutha, amafutha, uthuli, nezinsalela zokunamathela.

• Indlela Yokuhlanza:Sula indawo ehlanganyelwe ngendwangu engena-lint efakwe ku-solvent eguquguqukayo njenge-acetone noma u-99% we-isopropyl alcohol ngokushesha ngaphambi kokushisela.

Ukwenza Umshini Kahle: Ukuthuthukisa Imingcele Yokushisela Okubalulekile

Ukufeza i-weld ephelele kudinga ukulinganisa okuguquguqukayo okuningana okuxhumene.

I-Parameter Triad: Amandla, Isivinini, kanye Nesikhundla Sokugxila

Lezi zilungiselelo ezintathu ngokuhlangene zinquma okokufaka kwamandla kanye nephrofayela ye-weld.

• Amandla e-Laser (W):Amandla aphezulu anika amandla ukungena okujulile kanye nesivinini esisheshayo. Kodwa-ke, amandla amaningi angabangela ukusha ezintweni ezincane.

• Isivinini sokushisela (mm/s):Isivinini esisheshayo sinciphisa okokufaka kokushisa nokuhlanekezela. Uma isivinini siphezulu kakhulu kuleveli yamandla, singaholela ekungeneni okungaphelele.

• Indawo okugxilwe kuyo:Lokhu kulungisa usayizi wendawo we-laser kanye nokuminyana kwamandla. Ukugxila endaweni kudala ukushisela okujulile, okuncane kakhulu. Ukugxila ngenhla kwendawo (positive defocus) kudala ukushisela kwezimonyo ezibanzi, ezingashoni kakhulu. Ukugxila ngaphansi kwendawo (i-negative defocus) kungathuthukisa ukungena ezintweni eziwugqinsi.

Ukukhethwa Kwegesi Yokuvikela: I-Argon vs. Nitrogen

Ukuvikela igesi ivikela i-weld pool encibilikisiwe ekungcoleni komoya futhi kuzinzisa inqubo.

• I-Argon (Ar):Ukukhetha okuvame kakhulu, ukuhlinzeka ngokuvikeleka okuhle kakhulu nokukhiqiza ama-welds azinzile, ahlanzekile.

• I-nitrogen (N2):Ngokuvamile kuthandwa insimbi engagqwali, njengoba ingathuthukisa ukumelana nokugqwala kwelunga lokugcina.

• Isilinganiso sokugeleza:Izinga lokugeleza kufanele lithuthukiswe. Okuncane kakhulu kuzohluleka ukuvikela i-weld, kuyilapho okuningi kungadala isiyaluyalu futhi kudonse ukungcola. Izinga lokugeleza lamalitha ayi-10 kuye kwangama-25 ngomzuzu (L/min) liyibanga elijwayelekile lokuqala.

Ipharamitha Amaphuzu Okuqala: Ithebula Lereferensi

Okulandelayo amaphuzu ajwayelekile okuqala okushisela i-304/316 austenitic stainless steel. Njalo yenza izivivinyo ezintweni ezilahliwe ukuze ucule kahle uhlelo lwakho lokusebenza oluthile.

Ukulawula Ikhwalithi: Umhlahlandlela Wokuxazulula Izinkinga Zokukhubazeka Okujwayelekile

Ngisho nenqubo enembile, amaphutha angenzeka. Ukuqonda imbangela yabo kuyisihluthulelo sokuvimbela.

Ukuhlonza Ukukhubazeka Okujwayelekile Kwe-Laser Welding

• I-Porosity:Amabhamuza amancane egesi avaleleke ku-weld, ngokuvamile okubangelwa ukungcoliswa kwendawo noma ukugeleza kwegesi okuvimbele okungafanele.

• Ukuqhekeka Okushisayo:Ukuqhekeka kwe-centerline okwakheka njengoba i-weld iqina, kwesinye isikhathi ngenxa yokwakheka kwezinto noma ingcindezi ephezulu yokushisa.

• Ukungena Okungaphelele:I-weld ihluleka ukuhlangana kukho konke ukujula kwelunga, ngokuvamile kusuka emandleni anganele noma isivinini eseqile.

• I-Undercut:I-groove incibilika ensimbi eyisisekelo emaphethelweni e-weld, ngokuvamile ebangelwa isivinini esikhulu noma igebe elikhulu.

• I-Spatter:Amaconsi ancibilikisiwe akhishwa ku-weld pool, ngokuvamile kusukela ekuminyana kwamandla amaningi noma ukungcoliswa kwendawo.

Ishadi lokuxazulula izinkinga: Izimbangela Nezixazululo

Izinyathelo Zokugcina: Ukuhlanza Kwangemva Kokushisela kanye Nokwedlula

Inqubo yokushisela ilimaza zona kanye izakhiwo ezenza insimbi engagqwali “ingabi nasici.” Ukuzibuyisela kuyisinyathelo sokugcina esiyisibopho.

Kungani Ungeke Weqe Ukwelashwa Kwangemva Kwe-Weld

Ukushisa okuvela ekushiseleni kubulala ungqimba olungabonakali, oluvikelayo lwe-chromium-oxide endaweni yensimbi. Lokhu kushiya i-weld kanye ne-HAZ ezungezile engozini yokugqwala nokugqwala.

Izindlela Zokudlula Zichaziwe

I-Passivation iwukwelapha ngamakhemikhali okususa ukungcola okungaphezulu futhi kusize ukulungisa ungqimba oluqinile, olufana ne-chromium-oxide.

• I-Chemical Pickling:Indlela yendabuko esebenzisa ama-asidi ayingozi njenge-nitric ne-hydrofluoric acid ukuhlanza nokudlula indawo engaphezulu.

• Electrochemical Cleaning:Indlela yesimanjemanje, ephephile, futhi esheshayo esebenzisa uketshezi lwe-electrolytic oluncane kanye ne-low-voltage current ukuhlanza nokudlula ukushisela ngesinyathelo esisodwa.

Ukuphepha Okokuqala: Izinyathelo Ezibalulekile Zokushisela I-Laser

Imvelo yamandla aphezulu we-laser welding yethula izingozi ezinkulu zomsebenzi ezidinga imithetho eqinile yokuphepha.

Ingozi Efihliwe: I-Hexavalent Chromium (Cr(VI)) I-Fumes

Uma insimbi engagqwali ishiselwa kumazinga okushisa okushisela, i-chromium kungxubevange ingakha i-chromium ene-hexavalent (Cr(VI)), eba emoyeni emsini.

• Izingozi Zezempilo:I-Cr(VI) iwumdlavuza owaziwayo womuntu oxhumene nengozi eyandayo yomdlavuza wamaphaphu. Kungase futhi kubangele ukuphefumula okukhulu, isikhumba, nokucasuka kwamehlo.

• Imikhawulo Yokuchayeka:I-OSHA isetha umkhawulo oqinile Wokuchayeka Okuvunyelwe (i-PEL) wama-micrograms angu-5 kuyi-cubic mitha yomoya (5 µg/m³) ku-Cr(VI).

Izinyathelo Zokuphepha Ezibalulekile

• Izilawuli zobunjiniyela:Indlela ephumelela kakhulu yokuvikela abasebenzi ukubamba ingozi emthonjeni wayo. Ukusebenza kahle okuphezuluuhlelo lokukhipha intuthungesihlungi se-HEPA esinezigaba eziningi sibalulekile ukuze sithwebule izinhlayiya ze-ultrafine ezikhiqizwe ukushiselwa kwe-laser.

• Izinto Zokuzivikela Zomuntu Siqu (PPE):Bonke abasebenzi endaweni kufanele bagqoke izibuko zokuphepha ezilinganiselwe ngobude obuthile be-laser. Uma ukukhipha intuthu kungeke kunciphise ukuchayeka ngaphansi kwe-PEL, ama-respirators agunyaziwe ayadingeka. Umsebenzi wokushisela kufanele futhi uqhutshwe endaweni ebiyelwe evikela ukukhanya enezikhiye zokuphepha ukuvikela ukuchayeka kwemishayo ngengozi.

Imibuzo Evame Ukubuzwa (FAQ)

Iluphi uhlobo olungcono kakhulu lwe-laser lokushisela insimbi engagqwali?

Ama-laser e-fiber ngokuvamile ayisinqumo esingcono kakhulu ngenxa yobude bawo obufushane begagasi, obumuntshwa kalula yinsimbi engagqwali, kanye nekhwalithi yawo enhle kakhulu yohlaka lokulawula okunembayo.

Ungakwazi yini ukushisela nge-laser ugqinsi oluhlukene lwensimbi engagqwali ndawonye?

Yebo, i-laser welding iphumelela kakhulu ekuhlanganiseni ugqinsi olungafani ngokuhlanekezela okuncane futhi akukho ukushiswa engxenyeni ezacile, umsebenzi onzima kakhulu nge-TIG yokushisela.

Ingabe i-filler wire iyadingeka ukuze i-laser welding steel stainless steel?

Ngokuvamile, cha. I-laser welding ingakhiqiza ama-welds aqinile, angena ngokugcwele ngaphandle kwezinto zokugcwalisa (ngokuzenzakalelayo), okwenza inqubo ibe lula. I-filler wire isetshenziswa lapho umklamo ohlangene unegebe elikhudlwana noma lapho kudingeka izakhiwo ezithile ze-metallurgical.

Yibuphi ubukhulu obukhulu bensimbi engagqwali engashiselwa nge-laser?

Ngamasistimu anamandla amakhulu, kuyenzeka ukushisela insimbi engagqwali ifike ku-1/4″ (6mm) noma ugqinsile endaweni eyodwa. Izinqubo ze-laser-arc ezihlanganisiwe zingashisela izigaba ngogqinsi lweyintshi eyodwa.

Isiphetho

Izinzuzo zokushisela nge-laser ngesivinini, ukunemba, kanye nekhwalithi zikwenza kube ukukhetha okuphezulu kokwenziwa kwensimbi engagqwali yesimanje. Ikhiqiza amalunga aqinile, ahlanzekile anokuhlanekezeka okunganakwa, okugcina ubuqotho nokubukeka kwempahla.

Nokho, ukuzuza le miphumela esezingeni lomhlaba kuncike endleleni ehlangene. Impumelelo isiphetho sochungechunge lokukhiqiza olunembayo eliphezulu—kusuka ekulungiseleleni ngokuhlanganyela ngokucophelela kanye nokulawulwa kwepharamitha okuhlelekile kuya ekudluleni kokushiselwa okuphoqelekile kanye nokuzinikela okungantengantengi ekuphepheni. Ngokwazi kahle le nqubo, ungavula ileveli entsha yokusebenza kahle nekhwalithi emisebenzini yakho.