目的 探究高扫描速度（300 mm/s）下,直线形、圆形和“8”字形3种激光摆动方式对可调模式光束（Adjustable Mode Beam,AMB）激光焊接焊缝质量的影响规律及机制,为工艺优化提供依据。方法 采用AMB双光束激光器,对32层的6 μm厚铜箔与0.2 mm厚镀镍铜片（镀镍层0.1 μm）进行叠焊试验。通过金相分析熔深、熔宽及气孔率;利用高速摄像和落尘采集纸观测飞溅行为;测试焊缝电阻与抗拉剪性能,并计算波动性来评估工艺适用性;结合MATLAB计算能量分布,揭示不同摆动方式对焊缝成形及质量的影响机制。结果 与不摆动相比,直线形摆动方式下焊缝气孔率降低1.9%,飞溅数量少且尺寸较小,熔深波动性降低4.1%,电阻值最低且抗拉剪性能最高,性能波动最小。圆形和“8”字形摆动方式均导致气孔缺陷加剧,并出现大尺寸飞溅,电阻升高且抗拉剪性能下降,波动性显著增大。能量分布计算显示,圆形和“8”字形摆动方式因轨迹重叠/交叉产生局部能量过高、能量分布不均的现象;直线形摆动能量分布均匀。结论 在高焊速下,摆动频率与焊速不匹配会导致非直线形摆动周期无法有效交互,产生局部能量累积,加剧焊缝缺陷。直线形摆动因路径简单、无重叠交叉、能量分布均匀,可获得最佳焊接质量与工艺可重复性。在本试验参数条件下,与其他2种摆动方式相比,高扫描速度下直线形激光摆动方式是更好的选择。
Abstract
The work aims to investigate the effect laws and mechanisms of three laser oscillation modes (linear, circular, and 8-shaped) on the weld quality of AMB (Adjustable Mode Beam) laser welding at a high scanning speed of 300 mm/s, so as to provide a basis for process optimization. An AMB laser was used to perform stack welding experiments on a 32-layer copper foil with a thickness of 6 μm and a 0.2 mm-thick nickel-plated copper sheet (with a nickel plating layer of 0.1 μm). Metallographic analysis was conducted to measure penetration depth, weld width, and porosity. High-speed camera and spatter collection paper were used to observe spatter behavior. Weld resistance and shear force were tested, and their fluctuations were calculated to evaluate process applicability. Energy distribution was calculated with MATLAB to reveal the effect mechanism of different oscillation modes on weld formation and quality. The linear oscillation mode reduced porosity by 1.9% compared to non-oscillation mode and produced fewer spatters with smaller sizes, reduced penetration depth fluctuation by 4.1%, achieved the lowest resistance and the highest shear force, and showed the smallest performance fluctuation. The circular and 8-shaped oscillation modes both increased porosity defects, generated large spatters, increased resistance, decreased shear force, and significantly increased fluctuation. Energy distribution calculation showed that the latter two modes had local energy accumulation and uneven distribution due to track overlap or crossing. The linear oscillation had uniform energy distribution. At high welding speed, the mismatch between oscillation frequency and welding speed prevents non-linear oscillation cycles from interacting effectively, causing local energy accumulation and exacerbating weld defects. The linear oscillation, with its simple path and no overlap or crossing, provides uniform energy distribution and achieves the best welding quality and process repeatability. Therefore, the linear oscillation is a better choice than the other oscillation modes at high welding speed.
关键词
AMB激光焊接 /
激光摆动方式 /
多层铜箔 /
高焊速
Key words
AMB laser welding /
laser oscillation mode /
multi-layer copper foils /
high welding speed
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基金
安徽省重大科技攻关项目（2023z020003）; 国家自然科学基金（52505366）; 中国博士后科学基金（2024M764175）
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