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Method for high accuracy measurements of energy coupling and melting efficiency under welding conditions

: Hipp, Dominik; Mahrle, Achim; Jäckel, Sebastian; Beyer, Eckhard; Leyens, Christoph; Füssel, Uwe

Fulltext urn:nbn:de:0011-n-4802182 (1.0 MByte PDF)
MD5 Fingerprint: c875ff337fa4ae19e2f6015361fc38ae
Created on: 30.11.2018

Laser Institute of America -LIA-:
ICALEO 2017, 36th International Congress on Applications of Lasers & Electro-Optics. Online resource : October 22-26, 2017
Orlando, Fla.: LIA, 2017
ISBN: 978-1-940168-14-2
Paper 1204, 10 pp.
International Congress on Applications of Lasers & Electro-Optics (ICALEO) <36, 2017, Atlanta/Ga.>
Deutsche Forschungsgemeinschaft DFG
BE 1875/34-1
Experimentelle und theoretische Analyse des Tiefschweißeffektes beim lasergestützten Plasmaschweißen
Deutsche Forschungsgemeinschaft DFG
Experimentelle und theoretische Analyse des Tiefschweißeffektes beim lasergestützten Plasmaschweißen
Conference Paper, Electronic Publication
Fraunhofer IWS ()

The demands on production processes vastly increased in the last decade. Beside the fulfillment of the fabrication task, a process has to be energy efficient and resource saving to be in line for mass production. For the evaluation of competing technologies or for the optimization of a process regarding these requests the knowledge about the specific process efficiency is crucial. However, the value strongly depends on the chosen process parameters and the environmental conditions, wherefore documented values in literature are inapplicable. Hence, an experimental determination for each individual case is inevitable. Existing methods for the estimation of the process efficiency are either inaccurate or time and cost intensive. Therefore a new method for determining process efficiencies for almost arbitrary materials and process conditions is presented. The method bases on process observation using thermographic imaging and a subsequent adjusted numerical computation of temperature fields. The result of the numerical calculation in combination with the evaluation of the weld seam cross section is the value for the energy coupling efficiency, melting efficiency as well as the overall thermal efficiency. The features of the proposed method are evaluated with a Design of Experiments (DoE) approach. The technique is applied to a conventional laser and plasma welding process as well as to laser-assisted plasma arc welding. In comparison to the individual processes, the laser-assisted plasma arc welding shows a more than doubled overall thermal efficiency, which can be ascribed to a drastic increase in melting efficiency and a moderate increase in energy coupling efficiency.