Reduced pressure laser weld comparison to electron beam welds in Ti-6Al-4 V

Abstract

Reduced pressure laser welds were made using a 6-kW commercial fiber-laser system on Ti-6Al-4 V and compared to electron beam welds of the same beam diameters as measured by beam diagnostics. The laser welds showed keyhole characteristics under easily achievable mechanical pumped vacuum levels of 1 mbar pressure that nearly matched the electron beam weld penetrations made at 9 × 10–5 mbar vacuum. Ti-6Al-4 V alloys were used to represent refractory metals such as vanadium, tantalum, zirconium, or molybdenum that require vacuum or highly protective inert gas protection systems to prevent adverse interactions with air and can be difficult to weld under non-vacuum conditions. Results show that laser weld depths of 20 mm with aspect ratios of 17:1 can be made under what appears to be stable keyhole behavior as the result of reduced pressure. The effect of fiber diameter was examined using 0.1-, 0.2-, and 0.3-mm fibers, showing that small spot sizes can easily be achieved at long focal length lenses of 400 and 500 mm. The 0.1- and 0.2-mm fibers produced keyhole welds with minimal amounts of porosity, which was only present at 2 kW or higher, while the 0.3-mm fiber produced keyhole welds with more rounded roots that were porosity free as shown by radiography up to the maximum power of 6 kW. Correlations between weld depth and processing conditions are presented for the reduced pressure laser. These results are directly compared to electron beam welds, facilitating design of future reduced pressure laser systems targeted for deep weld penetrations historically developed for electron beams.