Post by Tjalling de Boer

#emobilityMondays at Coherent Corp. 🔬 Advancing Laser Welding: Keyhole Dynamics & Spatter Control In high-power laser beam welding of high-alloyed steels like AISI 304, spatter formation remains a major challenge—especially at welding speeds above 8 m/min. These molten ejections compromise weld quality and increase post-processing costs. Our latest collaborative study—led by Ilmenauer Fertigungstechnik TU Ilmenau , ESRF - The European Synchrotron, and Coherent Corp.—investigates how a local gas flow directed at the keyhole rear wall affects spatter behavior. Using high-speed synchrotron X-ray imaging at 40,000 fps, we gained unprecedented insight into the internal dynamics of the welding process. 🔧 Key Observations Top-side spatter was significantly reduced with local gas flow. At higher flow rates, the keyhole elongated, and hump formation occurred. Bottom-side spatter mechanisms were visualized for the first time. Gas flow helped stabilize keyhole collapse, reducing violent ejections. 🎥 Imaging the Invisible Experiments at ESRF beamline ID19 enabled real-time visualization of keyhole behavior and melt pool dynamics. This level of detail is unattainable with conventional diagnostics and is crucial for understanding and optimizing laser beam welding processes. 🤝 A Model for Collaboration This research was made possible through a strong academic–industrial partnership: TU Ilmenau: Scientific leadership ESRF: Advanced imaging capabilities Coherent Corp.: High-power #ARMFL and industrial insight Supported by FOSTA - Forschungsvereinigung Stahlanwendung e. V. and the Federal Ministry for Economic Affairs and Energy (BMWi) via IGF project 21413 BR, this work contributes to Germany’s industrial cooperative research efforts. ✅ Key Takeaways 🔹 Material: AISI 304 stainless steel 🔹Laser: High-power ARM-FL8 8kW fibre laser from Coherent Corp. 🔹Gas flow reduces top-side spatter and alters keyhole dynamics 🔹Synchrotron imaging reveals internal spatter mechanisms 🔹Collaborative research drives innovation in laser welding Understanding the physics of laser–material interaction is key to improving weld quality, efficiency, and reliability. This study marks a step forward in developing cleaner, more stable Laser Beam Welding processes. 👉 Read the full article in Elsevier's Optics and Laser Technology https://lnkd.in/e8i5bNfY https://lnkd.in/eEjECsZy