Mechanisms of Spatter Formation and Suppression in Aluminum Alloy via Hybrid Fiber–Semiconductor Laser System

This study investigates the spatter suppression mechanism in aluminum alloy welding using a hybrid fiber–semiconductor laser system. By integrating high-speed photography and three-dimensional thermal-fluid coupling numerical simulations, the spatter formation process and its suppression mechanisms were systematically analyzed. The results indicate that spatter formation is primarily governed by surface tension and recoil pressure. In single fiber laser welding, concentrated laser energy induces a steep temperature gradient on the molten pool surface, triggering a strong Marangoni effect and subsequent spatter generation. In contrast, the hybrid laser system optimizes energy distribution, reducing the temperature gradient and weakening the Marangoni effect, thereby suppressing spatter. Additionally, the hybrid laser stabilizes molten pool flow through uniform recoil pressure distribution, further inhibiting spatter formation. Experimental results demonstrate that the hybrid fiber–semiconductor laser system significantly reduces spatter, improving welding quality and stability. This study provides theoretical and technical support for optimizing aluminum alloy laser welding.