Study on the Influence of Laser Cladding Welding Parameters on the Welding Quality of Ultra-Fine Bridge Wire
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摘要:为探究极细桥丝激光熔覆焊接过程中桥丝与熔池边沿的温度及热力学特性，优化极细桥丝激光熔覆焊接工艺参数，采用Ansys Fluent有限元仿真软件对直径为13 μm的Ni-Cr桥丝在120，150，180，200 W激光功率及-3～3 mm离焦量下的焊接过程进行仿真，分析了激光功率及离焦量对桥丝与熔池边沿的温度及热应力的影响，并对不同激光功率及离焦量下的桥丝焊接效果进行了实验研究。结果表明：120 W激光功率下，焊点连接不牢固；150 W激光功率下，焊点牢固且表面光滑，桥丝保持完整无断裂；180 W激光功率下，过高的熔池边沿温度与热应力增加了桥丝断裂风险，焊点表面出现氧化变色；200 W激光功率下，桥丝与熔池边沿的温度及热应力超过了桥丝的性能极限，桥丝断裂，并损伤基底，引起金属飞溅，严重影响焊点质量。当激光功率为150 W、脉宽为2 ms、离焦量为-2 mm时，焊接效果最佳。
Abstract:In order to investigate the temperature and thermodynamic characteristics of the bridge wire and the edge of the molten pool during the laser cladding welding process of ultra-fine bridge wire, and optimize the laser cladding welding process parameters of ultra-fine bridge wire, Ansys Fluent finite element simulation software was used to simulate the welding process of Ni-Cr bridge wire with a diameter of 13 μm at a laser power of 120, 150, 180, 200 W and a defocus amount of -3～3 mm. The influence of laser power and defocus amount on the temperature and thermal stress at the bridge wire and the edge of the molten pool was analyzed, and the welding effect of bridge wire under different laser power and defocus amount was experimental studied. The results show that under a laser power of 120 W, the solder joint is not firmly connected; At a laser power of 150 W, the solder joint is firm and the surface is smooth, and the bridge wire remains intact without breakage; At a laser power of 180 W, the excessively high temperature and thermal stress at the edge of the molten pool increase the risk of bridge wire fracture, and cause oxidation discoloration on the surface of the solder joint; At a laser power of 200 W, the temperature and thermal stress at the bridge wire and the edge of the molten pool exceed the performance limit of the bridge wire, causing the bridge wire to break and damage the substrate, resulting in metal splashing and seriously affecting the quality of the solder joint. When the laser power is 150 W, the pulse width is 2 ms, and the defocus amount is -2 mm, the welding effect is optimal.
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