CAREER: Vibration-Assisted Laser Keyhole Welding to Improve Joint Properties

职业：振动辅助激光小孔焊接可改善接头性能

• 批准号: 1752218
• 负责人: Wenda Tan
• 金额: $ 50万
• 依托单位: University of Utah
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2018
• 资助国家: 美国
• 起止时间: 2018-04-01 至 2022-04-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1752218&HistoricalAwards=false
• 关键词: CAREER; Vibration; Assisted; Laser; Keyhole

Welding-critical industries represent about one-third of the Gross Domestic Product (GDP) of the United States, and as such this project on vibration-assisted laser keyhole welding advances the national prosperity and welfare; it also has numerous defense applications so that this project secures the national defense. Any improvements in welding productivity and performance can potentially save billions of dollars for the country. Laser welding is a promising process that can improve the welding speed by tens and even hundreds of times compared with conventional welding processes such as arc welding and electric resistance welding. However, laser welding can suffer from several problems, including high porosity, coarse grains, and brittle intermetallic compounds in the joints, all of which can reduce performance. This Faculty Early Career Development Program (CAREER) project is focused on a novel process called Vibration-assisted Laser Keyhole Welding (V-LKW) and aims to study how the laser vibration will help to solve the aforementioned problems in laser welding. Experimentation and numerical modeling will be used simultaneously to investigate the fundamental physics in V-LKW. The research, if successful, will significantly advance scientific understanding of the complex phenomena in V-LKW, and promote the applications of this novel process in the manufacturing industry (especially the automotive and aerospace sectors) for the improvement of welding productivity and performance. The educational objective of this project is to engage and prepare students for the intellectual challenges in modern manufacturing technologies. Outreach activities to high school students will be conducted to cultivate their interests in manufacturing technology and encourage them to explore engineering as their future careers.This CAREER project will focus on a novel Vibration-assisted Laser Keyhole Welding (V-LKW) process. The research objective is to test the hypothesis that the properties of V-LKW joints can be significantly improved through the mechanisms of porosity reduction, grain refinement, and intermetallic reduction, all of which are functions of the vibration direction, amplitude, and frequency of the laser. In-process time-resolved observation techniques, post-process microstructural/mechanical characterization methods, and a multi-physics numerical model will be used to identify the process-structure-property relationship of V-LKW and understand the fundamental physics in V-LKW. If successful, this project will advance our understanding of laser-matter interaction, keyhole dynamic behavior, vibration generation/transmission, multi-phase thermo-fluid flow, and solidification phenomena in V-LKW. The research will enable the improvement of welding productivity and joint properties in the manufacturing of many products, including but not limited to automobiles, thermal management devices, electronic devices, and medical devices. The outreach and education activities will improve the education of manufacturing science and engineering at the University of Utah, attract more high school, college, and minority students to choose careers in engineering and manufacturing, and strength the university's connection to local communities. Research results will be disseminated in a timely manner through journal/conference publications and interactions with industries.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

关键焊接行业约占美国国内生产总值（GDP）的三分之一，因此，该项目涉及振动辅助的激光钥匙孔焊接，可以提高国家繁荣和福利；它还具有许多国防申请，因此该项目可以保护国防。焊接生产率和性能的任何改善都可以为该国节省数十亿美元。激光焊接是一个有前途的过程，与传统的焊接过程（例如电弧焊接和电阻焊接）相比，可以提高焊接速度甚至数百次。 但是，激光焊接可能会遇到几个问题，包括高孔隙率，粗晶粒和关节中的金属间化合物，所有这些都可以降低性能。该教师早期职业发展计划（职业）项目的重点是一个称为振动辅助激光钥匙孔焊接（V-LKW）的新型过程，旨在研究激光振动将如何帮助解决激光焊接中上述问题。实验和数值建模将同时使用V-LKW中的基本物理。这项研究，如果成功的话，将显着提高对V-LKW中复杂现象的科学理解，并促进这一新过程在制造业（尤其是汽车和航空航天部门）中的应用，以提高焊接生产力和性能。该项目的教育目标是吸引和准备学生应对现代制造技术的智力挑战。将向高中生进行外展活动，以培养他们对制造技术的兴趣，并鼓励他们在未来的职业中探索工程学。该职业项目将重点放在新型的振动辅助激光钥匙孔焊接（V-LKW）上。研究目的是检验以下假设：通过孔隙率还原，晶粒细化和金属间还原的机制可以显着改善V-LKW接头的性能，所有这些都均是激光器的振动方向，振幅和频率的功能。进程时间分辨的观察技术，后过程的微观结构/机械表征方法以及多物理数值模型将用于识别V-LKW的过程结构结构 - 培训关系，并了解V-LKW中的基本物理学。如果成功的话，该项目将提高我们对激光 - 物体相互作用，钥匙孔动态行为，振动产生/传播，多相热流体流动和V-LKW中凝固现象的理解。这项研究将使焊接生产率和联合特性在许多产品的制造中提高，包括但不限于汽车，热管理设备，电子设备和医疗设备。宣传和教育活动将改善犹他大学的制造科学和工程学教育，吸引更多的高中，大学和少数族裔学生选择工程和制造业的职业，并加强大学与当地社区的联系。研究结果将通过期刊/会议出版物和与行业的互动及时传播。该奖项反映了NSF的法定任务，并被认为是值得通过基金会的知识分子优点和更广泛的影响评估标准通过评估来支持的。

项目成果

Effect of Laser-Matter Interaction on Molten Pool Flow and Keyhole Dynamics

• DOI: 10.1103/physrevapplied.11.064054
• 发表时间: 2019-06-24
• 期刊: PHYSICAL REVIEW APPLIED
• 影响因子: 4.6
• 作者: Kouraytem, Nadia;Li, Xuxiao;Tan, Wenda
• 通讯作者: Tan, Wenda

Bulk-Explosion-Induced Metal Spattering During Laser Processing

• DOI: 10.1103/physrevx.9.021052
• 发表时间: 2019-06
• 期刊: Physical Review X
• 影响因子: 12.5
• 作者: Cang Zhao;Qilin Guo;Xuxiao Li;N. Parab;K. Fezzaa;W. Tan;Lianyi Chen;T. Sun

Critical instability at moving keyhole tip generates porosity in laser melting

• DOI: 10.1126/science.abd1587
• 发表时间: 2020-11-27
• 期刊: SCIENCE
• 影响因子: 56.9
• 作者: Zhao, Cang;Parab, Niranjan D.;Sun, Tao
• 通讯作者: Sun, Tao

Energy-Coupling Mechanisms Revealed through Simultaneous Keyhole Depth and Absorptance Measurements during Laser-Metal Processing

• DOI: 10.1103/physrevapplied.13.064070
• 发表时间: 2020-06-29
• 期刊: PHYSICAL REVIEW APPLIED
• 影响因子: 4.6
• 作者: Allen, Troy R.;Huang, Wenkang;Simonds, Brian J.
• 通讯作者: Simonds, Brian J.

Investigation of metal mixing in laser keyhole welding of dissimilar metals

• DOI: 10.1016/j.matdes.2020.109056
• 发表时间: 2020-10-01
• 期刊: MATERIALS & DESIGN
• 影响因子: 8.4
• 作者: Huang, Wenkang;Wang, Hongliang;Tan, Wenda
• 通讯作者: Tan, Wenda