About this Abstract |
| Meeting |
2027 TMS Annual Meeting & Exhibition
|
| Symposium
|
Advanced Real Time Imaging for Materials Science and Processing: 10th Anniversary
|
| Presentation Title |
Keyhole Dynamics and Defects Formation during Laser Welding of Aluminium |
| Author(s) |
Zhengrui Tao, Jiahui Zhang, Tristan Fleming, Sebastian Marussi, Andrey Gorskiy, Aleksandr Oreshkin, Emma Howard, Kwan Kim, Shishira Bhagavath, Chuzhe Song, Alexander Rack, Diego Hopson Safatli, Iurii Markushov, Jang Griffin, Chinnapat Panwisawas, Peter D. Lee, Chu Lun Alex Leung |
| On-Site Speaker (Planned) |
Zhengrui Tao |
| Abstract Scope |
High-power laser welding of aluminium is central to electric vehicle manufacturing, yet keyhole instability and associated pore formation mechanisms remain difficult to control because of highly transient process dynamics. This study combines in situ synchrotron X-ray imaging with multiphysics process simulation to elucidate pore-forming mechanisms during high-power aluminium laser welding with and without beam shaping technologies. High-speed synchrotron X-ray imaging at 200 kHz enables direct visualisation of keyhole dynamics, melt pool evolution, and pore initiation across different process regimes. By integrating experimental observations with predicted pressure, temperature, and flow fields, three dominant pore-formation mechanisms are identified: rear-wall bulging pore, keyhole separation, and blowhole formation. This presentation will detail each of the underlying mechanisms. In the blowhole formation regime, a ring-mode beam reduces pore formation by enlarging the melt pool, capturing the ejected melt before solidification, minimising surface roughness in the weld parts. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Joining, |