相比于传统焊接方法，激光焊接具有显著的优势——热输入低、焊接速度快、热影响区小、热变形小等，近年来激光焊接得到了广泛的使用，在汽车工业、船舶工业、核电工业、航天航空工业等高科技行业应用的越来越广泛，而且随着成套设备成本的降低，在日常五金用品及其它生活相关领域的应用开始迅速增长。
Compared with traditional welding methods, laser welding has significant advantages such as low heat input, fast welding speed, small heat affected zone and small thermal deformation. In recent years, laser welding has been widely used, especially in the high-tech industries such as the automotive industry, the shipbuilding industry, the nuclear power industry, and the aerospace industry. Meanwhile, with the reduction in the cost of complete sets of equipment, applications in everyday hardware and other life-related fields are beginning to grow rapidly.
为了适应各行业发展的需求，激光焊接的方式方法也有改良进步。激光填丝焊因其焊接能量集中、变形小等特点，可以降低对接焊时的间隙裕度，减少焊接缺陷，成为轨道交通和汽车行业内，有效替代传统电弧焊的焊接方式。
本期【Rayclass | 锐课堂】就带您来认识一下激光填丝焊接的妙用。
In order to meet the needs of the development of various industries, the methods of laser welding have also improved. Due to its concentrated welding energy and small deformation, laser welding with filler wire can reduce the gap margin and welding defects. It has become an effective alternative to traditional arc welding in rail transit and automotive industries.
激光填丝焊时，激光器一般选用高功率光纤激光器。
Generally, high-power fiber laser has been selected while laser welding with filler wire.
锐科高功率光纤激光器
High-power CW Fiber Laser
激光不仅需要焊丝，还需要熔化母材并在母材上形成激光深熔焊特有的小孔效应，形成较深的熔池，焊丝成分与母材金属成分充分混合形成一种新的混合熔池，该混合熔池的元素成分及其比例、质量相对于焊丝与母材有较大的差别，所以可以针对母材本身的性能缺陷，选择合适的焊丝添加到焊接过程中，从而在微观层面上对焊缝的抗裂性、抗疲劳性、耐蚀性、耐磨性等方面进行有目的性的改善。
The laser not only needs the welding wire, but also needs to melt the base metal and form a special pore effect on the base metal to form a deep molten pool. The wire composition is thoroughly mixed with the base metal component to form a new mixed molten pool. The elemental composition of the mixed molten pool and its proportion and quality are largely different from those of the welding wire and the base material. Therefore, it is possible to select a suitable welding wire for the performance defect of the base material itself, and to improve the crack resistance, fatigue resistance, corrosion resistance and wear resistance of the weld at a microscopic level.
除此之外，激光填丝焊可以进行多道堆叠焊接，因为能够实现具有小孔效应的深熔焊，可以实现上下两层焊道的充分熔合，避免未熔合的严重缺陷，这样就具备焊接大厚度接头的能力。
In addition, laser welding with filler wire perform multiple stack welding because deep fusion welding with a small hole effect can be achieved. Due to the full fusion of the upper and lower weld beads, severe defects that are not fused are avoided, thus providing the ability to weld large thickness joints.
随着激光填丝焊技术的发展以及激光器功率上限的提高，激光填丝焊的应用范围越来越广泛：
With the development of laser welding with filler wire technology and the increase of laser power upper limit, the application range of laser filler wire welding is more and more extensive.
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激光填丝焊的应用领域 Application Field |
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激光填丝焊接铝合金 Aluminum Alloy Welding |
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2 |
激光填丝焊接异种金属 Dissimilar Metal Welding |
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3 |
改善焊缝成型 Improve Weld Formation |
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4 |
窄间隙填丝焊 Narrow Gap Filler Wire Welding |
其中，针对改善焊缝成型和窄间隙填丝焊这两个应用，我们用实际应用案例来看看激光填丝焊的效果。
Among them, for the two applications of improving weld formation and narrow gap filler welding, we use practical application cases to see the effect of laser filler welding.
改善焊缝成型
Improve Weld Formation
要求：1mm和3mm不锈钢拼焊，要求焊缝无气孔，成型较好。
Requirements: 1mm and 3mm stainless steel, weld seam without air holes, good molding.
设备：锐科4000W连续光纤激光器（光纤芯径200μm）、送丝机、焊接头。
Equipment: Raycus 4000W CW Fiber Laser (core diameter: 200μm), wire feeder, welding head.
工艺参数：如下表所示。
Parameters are shown in the following table.
|
接头厚度 Joint Thickness （mm） |
激光功率 Laser Power （W） |
焊接速度 Welding Speed （mm/s） |
送丝速度 Wire Feeder Speed （m/min） |
离焦量 Defocus （mm） |
|
1mm+1mm |
2500 |
35 |
1.2 |
+5 |
|
3mm+3mm |
4000 |
25 |
1.0 |
+5 |
|
1mm+3mm |
3100 |
35 |
1.5 |
+5 |
结果：成型较好，焊缝无气孔，如下图所示的焊缝成型及横截面形貌。
Results: The molding was good, and the weld was free of pores, as shown in the following figure for weld formation and cross-sectional morphology.
a. 1mm+1mm
b. 1mm+3mm
c. 3mm+3mm
窄间隙激光填丝多道焊接
Narrow Gap Laser Filling Multi-pass Welding
要求：18mm厚的Q345船用钢板拼焊，要求焊缝气孔较少，没有未熔合，接头抗拉强度高于母材，焊缝成型较好。
Requirements: The 18mm thick Q345 marine steel plate is welded, requiring less weld porosity, no unfusion, and the joint tensile strength is higher than that of the base metal, and the weld is well formed.
设备：锐科6000W连续光纤激光器（光纤芯径400μm）、送丝机、焊接头。
Equipment: Raycus 6000W CW Fiber Laser (core diameter: 400μm), wire feeder, welding head.
工艺参数：焊道必须开坡口，坡口尺寸如下图所示。
Parameters: The bead must be opened, and the groove size is shown in the figure below.
其他焊接工艺参数如下表所示。
Other welding process parameters are shown in the table below.
|
焊道次序 Sequence |
激光功率 Laser Power （W） |
焊接速度 Welding Speed （mm/s） |
送丝速度 Wire Feeder Speed （m/min） |
离焦量 Defocus （mm） |
|
1 |
6000 |
20 |
4 |
+4 |
|
2 |
5000 |
20 |
6 |
+10 |
|
3 |
5000 |
20 |
6 |
+10 |
|
4 |
5000 |
15 |
6 |
+10 |
|
5 |
6000 |
15 |
6 |
+15 |
结果：成型较好，没有出现未熔合，焊缝基本无气孔，如下图所示，并且经过拉伸试验证明，焊缝断裂在母材，说明接头抗拉强度高于母材。
Results: The molding was good, there was no unfusion, and the weld was basically free of pores, as shown in the figure below, and the tensile test proved that the weld was broken in the base metal, indicating that the tensile strength of the joint was higher than that of the base metal.
焊缝横截面金相图
weld cross section metallographic diagram
【Rayclass | 锐课堂】TIPS
针对常用材料的对接接头激光填丝焊，为了改善焊缝成型，一般推荐激光器及光纤芯径、焊接头配置应当保证聚焦光斑直径为0.4mm～0.6mm之间，并且焊丝应当选择适当的牌号。
For the laser welding bonding of common materials, in order to improve the weld formation, it is generally recommended that the laser and the fiber core diameter and the welding head configuration should ensure that the focal spot diameter is between 0.4mm and 0.6mm, and the wire should be selected with an appropriate grade.
