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An optimization method for defects reduction in fiber laser keyhole welding

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An Erratum to this article was published on 02 February 2016

Abstract

Laser welding has been widely used in automotive, power, chemical, nuclear and aerospace industries. The quality of welded joints is closely related to the existing defects which are primarily determined by the welding process parameters. This paper proposes a defects optimization method that takes the formation mechanism of welding defects and weld geometric features into consideration. The analysis of welding defects formation mechanism aims to investigate the relationship between welding defects and process parameters, and weld features are considered to identify the optimal process parameters for the desired welded joints with minimum defects. The improved back-propagation neural network possessing good modeling for nonlinear problems is adopted to establish the mathematical model and the obtained model is solved by genetic algorithm. The proposed method is validated by macroweld profile, microstructure and microhardness in the confirmation tests. The results show that the proposed method is effective at reducing welding defects and obtaining high-quality joints for fiber laser keyhole welding in practical production.

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Abbreviations

DOE:

Design of experiments

FZ:

Fusion zone

LP:

Laser power

WS:

Welding speed

FP:

Focal position

SG:

Shield gas

ANN:

Artificial neural network

GA:

Genetic algorithm

BPNN:

Back-propagation neural network

FD:

Front defects

HF:

Front height

BD:

Back defects

HB:

Back height

WF:

Front width

WB:

Back width

BH:

Bead height

BM:

Base material

F:

Focal length

BPP:

Beam parameter product

T:

Thickness

HAZ:

Heat affected zone

FAG:

Fine equiaxed grains

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Acknowledgments

This research has been supported by the National Natural Science Foundation of China (NSFC) under Grant No. 51323009, the National Basic Research Program (973 Program) of China under Grant No. 2014CB046703, the National Natural Science Foundation of China (NSFC) under Grant No. 51505163 and 51421062, and the Fundamental Research Funds for the Central Universities, HUST: Grant No. 2014TS040. The authors also would like to thank the anonymous referees for their valuable comments.

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Authors and Affiliations

  1. The State Key Laboratory of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, People’s Republic of China

    Yuewei Ai, Ping Jiang, Xinyu Shao, Peigen Li, Yang Liu & Wei Liu

  2. School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, People’s Republic of China

    Chunming Wang & Gaoyang Mi

Authors
  1. Yuewei Ai
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  2. Ping Jiang
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  3. Xinyu Shao
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  5. Peigen Li
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  7. Yang Liu
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  8. Wei Liu
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Correspondence to Ping Jiang.

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Ai, Y., Jiang, P., Shao, X. et al. An optimization method for defects reduction in fiber laser keyhole welding. Appl. Phys. A 122, 31 (2016). https://doi.org/10.1007/s00339-015-9555-8

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