Abstract
Earlier work predicted that the thermal efficiency, capillary stability, and thermomechanical loads can be improved by by significantly increasing the feed rate. This hypothesis was proved in the current work with X-ray videos and metallographic analysis of AlMgSi samples welded with the average laser power of 16 kW of a TruDisk 16002, feed rates >30 m/min, and a focal diameter of 630 µm. In case of welding with 50 m/min, the X-ray video analysis shows a very large opening of the capillary on the top. No pore formation was observed and the geometry of the capillary was constant without any fluctuations. The resulting longitudinal section is completely free of pores and shows a constant penetration depth - clearly demonstrating the benefit of high-speed welding with high average powers. An additional benefit of high-speed welding is that the thermomechanical load of the weld changes. In case of welding of AlMgSi alloys with 50 m/min no centerline hot cracks occurred at edge distances ≥ 3 mm. This cannot be realized with a conventional feed rate of 6 m/min and laser power of 5 kW.
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