Laser Welding of Roll-Formed Profiles: Process Optimization for Varying Thicknesses

This study investigates laser welding with specific relevance to roll-formed profiles of different thicknesses, i.e., 1.5 mm, 2.0 mm, 2.4 mm, and 2.7 mm. This study makes use of a high-power continuous-wave solid-state laser source combined with a sophisticated multi-axis laser welding system for easy welding. The ultimate objective of this comprehensive research was the successful creation of full penetration welds, all at high welding rates of more than 13 meters per minute, and thus the results were extremely relevant to industrial application. Experimental findings gained from the research study unequivocally exhibited that full penetration was successfully created at 15 meters per minute speed for thickness levels of 1.5 millimeters and 2.0 millimeters. However, it was observed that when thickness measurements of 2.4 millimeters and 2.7 millimeters were taken, the speed needed to be reduced to 13 meters per minute to obtain comparable results. Apart from this, the most important parameters critical to the process, i.e., laser power, core power, and focus position, were all optimized accordingly to achieve optimum results. The research work gives complete attention to the significance of proper joint preparation, with special stress on removing any gap or height mismatch so that high weld quality can be sustained throughout the process.