applied

sciences
Article
Application of Pulsed Laser-TIG Hybrid Heat Source
in Root Welding of Thick Plate Titanium Alloys
Jipeng Shi, Yanbin Zhou and Liming Liu *
Key Laboratory of Liaoning Advanced Welding and Joining Technology, School of Materials Science and
Engineering, Dalian University of Technology, Dalian 116024, China; shijp@mail.dlut.edu.cn (J.S.);
yanbinocean@mail.dlut.edu.cn (Y.Z.)
* Correspondence: liulm@dlut.edu.cn; Tel./Fax: +86-0411-8470-7817

Academic Editor: Stanislaw M. Dubiel

Received: 17 March 2017; Accepted: 26 April 2017; Published: 18 May 2017

Abstract: Laser-TIG (tungsten inert gas) hybrid welding process is applied to produce stable back
beads in the first layer during one-side multilayer welding. To explain why stable back beads can be
formed, a comparison is conducted between single TIG and laser-TIG hybrid welding. Results indicate
that during laser action the arc column is enhanced and deflected to the keyhole, which changes the
spatial distribution of plasma by strong attraction. The keyhole plasma possesses extreme electric
conductivity. After laser action, the enhanced arc is restituted, the low energy density arc acts on the
molten pool, and the bottom of the molten pool is solidified to prevent its collapse. The heat and force
are redistributed over the top of molten pool under the alternative action of the enhanced arc and
original arc. In this case the thermal distribution and mechanical situation in the molten pool must
be more balanced and reasonable, and the back bead appearance is continuous, stable and uniform.
This process gives high quality and efficient root welding of the thick plate.

Keywords: laser-TIG hybrid welding; root welding; deflected arc; alternative action

1. Introduction
Titanium alloys, which have already been considered as a kind of key developing structural
materials with great strategic significance by a number of the world’s dominant military powers,
have been used in substitution aluminum alloys and steels in the aerospace, ship and chemical
industries, etc., because they possess many good characteristics such as high strength to weight
ratio, corrosion resistance and excellent weld-ability [1,2]. In recent years, due to the need for nation
space science development, remarkable advances have been made in large-tonnage launch vehicles,
spaceports and other equipment, and we have come a long way in production capacity and technology
level of titanium alloys. The demand for titanium alloys with complex structural components with
large volume and thickness is constantly increasing [3,4]. The advanced welding technology, which is
considered as the common technique in components manufacturing, is one of the most attractive
problems in the joining field of titanium alloys [5]. As we all know, multilayer multi-channel welding
is a commonly used technology in conventional jointing of a thick mild plate. A stable formation of
continuous weld in the first layer during the welding process is important to achieve welded joints with
high quality and productivity [6]. Recently, several different welding methods have been developed
to jointing titanium alloy. However, each of these methods has its own significant imperfection.
Arc welding, which is the earliest method developed for titanium welding, has a low productivity.
The electron beam welding has a limitation on the overall dimensions of the weld workpieces due
to there the necessity of making a vacuum in the working chamber [7]. Laser welding, which is
considered as a high-efficiency method, is the most promising jointing method for thick plates [8].
Campanelli S.L. et al. reported that a satisfactory titanium alloy joint can be achieved at high welding

Appl. Sci. 2017, 7, 527; doi:10.3390/app7050527 www.mdpi.com/journal/applsci

Appl. Sci. 2017, 7, 527 2 of 12

speed by 1.2 KW laser welding process [9]. However, the laser welding process requires greater
precision in the positioning of the pieces to be jointed. Thus, the researchers are stimulated to look for
another welding process that has the ability to penetrate deeper into the workpiece and consequently
reduce total heat input.
Laser-arc hybrid heat source, which possesses many new and unique merits, such as improved
manufacturing stability, efficiency, quality and reduced energy consumption, is a mixed high energy
density laser with an arc of good gap tolerance forming an efficient welding method [10–12].
The addition of a laser beam can improve the arc stabilities, whereas the arc can also play an efficient
role in melting welding [13]. Thus, when the laser-arc hybrid welding was introduced, it attracted
much attention from researchers in titanium alloy manufacturing. Truichin G. suggested that the
technology of 5 KW laser-TIG welding with filler wire of titanium alloys with a thickness of 5 mm
has been developed [14]. By studying the 1.5 KW laser-TIG hybrid welding process of thick plate,
Zhang reported that a satisfactory weld can be obtained and the tension of the weld is higher than that
of the TA15 alloy [15]. By carrying out 2.15 KW laser-MIG on titanium, M. Brandizzi et al. indicated
that the weld appearance is sensitive to changes in the gap [11]. Liu, et al. published a paper in 2008,
in which titanium alloy with 2.0 mm was joined successfully by pulsed laser-TIG hybrid welding [16].
However, most of the literature is focused on the larger energy laser or thin plate welding process; for
root welding of thick plate titanium alloy, the literature is extremely limited [17].
In this study, root welding experiments were carried out on thick plate titanium alloys,
and an experimental system was developed to implement the laser-TIG hybrid welding process.
The authors investigated the regulatory effect of the pulsed laser on the thermal distribution and
mechanical situation in the molten pool. The vision system was employed to observe the weld arc
behaviors during the welding process. Another vision system was employed to observe the molten
pool during the welding process. The spectrograph was employed to acquire the plasma spectra.
The reason why stable back beads are formed by the hybrid welding process was explained.

2. Experimental Procedures

2.1. Equipment Setup

The experiments were performed at room temperature and atmospheric pressure. The heat source,
which is similar to our previous report [18], was the combination of a pulsed Nd: YAG laser beam and
a lateral-axial arc produced by a tungsten inert gas (TIG) welding machine, as schematically shown
in Figure 1. The laser, with the wavelength of 1.064 µm, was focused by a lens with a focal distance
of 120 mm into a spot measuring about 0.6 mm. The average output power of the laser beam was
within 0 to 1000 W by controlling the pulse energy, pulse duration and pulse frequency. In the hybrid
welding process, the arc operated continuously while the laser operated in the form of pulses as shown
in Figure 2. The workpiece was placed perpendicular to the laser beam. The angle of the tungsten
electrode axis to the target was kept 45◦ . In addition, titanium alloy is identified as a highly reactive
material at ambient gases, especially at high temperature. For this reason, during welding, a trailing
and back shielding gas was used to protect the both sides of the molten pool from oxidation.
The SP-2556 spectrograph (Princeton Instruments, Princeton, NJ, USA) with 500 mm focus was
used to acquire the plasma spectra. The fiber head was fixed to an X-Y controlled device, as shown
in Figure 1, which acquires the accuracy of 0.01 mm. Meanwhile, according to the welding plasma
spectrum and NIST (National Institute of Standards and Technology, Gaithersburg, MD, USA) database,
two narrow-band optical filters were employed to observe the distribution of Ti and Ar atoms in
the plasma, as shown in Figure 3a. As shown in Figure 3a, the spectrum of the hybrid welding arc
plasma with the wavelength from 200 to 1000 nm is acquired. It also can be seen that the arc plasma
is mainly composed of Ti atoms, Ar atoms, Ti+ ions and Ar+ ions. In this research, three lines of Ti
atoms (Ti I 439.39 nm, Ti I 441.73 nm and Ti I 521.04 nm) are selected to characterize the arc plasma in
welding. In order to further study the plasma behavior, plasma spectrum at different locations in the
Appl. Sci. 2017, 7, 527 3 of 12
Appl. Sci. 2017, 7, 527 3 of 12
Appl. Sci. 2017, 7, 527 3 of 12
Appl. Sci. 2017, 7, 527 3 of 12
arc plasma in welding. In order to further study the plasma behavior, plasma spectrum at different
vertical
arc planein
plasma was acquired
welding. In and analyzed,
order to further as
studyshown
the in Figure
plasma 3b. In this
behavior, process,
plasma the adjustment
spectrum at different of
locations in the vertical plane was acquired and analyzed, as shown in Figure 3b. In this process, the
arc plasma
thelocations
fiber head in
in thewelding.
distance is
vertical In2 order
mm to
each further
time study
along the
the Yplasma
axis behavior,
from 0 mm plasma
to 4 mm spectrum
and 1 mmat different
each time
adjustment of the fiber plane was acquired
head distance is 2 mm andeach
analyzed, as shown
time along the Yinaxis
Figure
from3b. In this
0 mm to process,
4 mm and the1
locations
along the X
adjustment in thefrom
axis
of vertical
the 0 mm
fiber plane
head to 7was
mm acquired
distancein the
is 2 andeach
analyzed,
coordinate
mm plane,
time aswhere
alongshown
the in Figure
position
Y axis from 3b.
(0, 0)
0 In
mm this
was to process,
the
4 the
intersection
mm and 1
mm each time along the X axis from 0 mm to 7 mm in the coordinate plane, where position (0, 0) was
adjustment
mm
of the each
base of the
time
metal alongfiber
the
surface head
X
and axisdistance
thefrom
axis 0 is
mm
of 2 mm
to
laser 7 each
mm
beam time
in
andthe along the(0,
coordinate
position Y plane,
axis
4) is from
thewhere0 mm toof4 the
position
position mm
(0, and
0) was
tungsten1
the intersection of the base metal surface and the axis of laser beam and position (0, 4) is the position
mmintersection
the each
electrode time
tip. Thealong
of thethe X temperature
base
electron axis
metalfrom 0 mm
surface of to
and 7the
every mm in of
axis thelaser
position coordinate
was beam plane,
and
calculated where
position
and position
(0,
the 4) is the
calculated (0, 0)results
was
position
of the tungsten electrode tip. The electron temperature of every position was calculated and the
thethe
of intersection
tungsten of the basetip.
electrode metalThesurface
electronandtemperature
the axis of laser beam position
ofUSA).
every and position (0, 4) is the position
were fitted
calculated byresults
MATLAB were(R2014a,
fitted by Mathworks,
MATLAB Natick,
(R2014a, MA,
Mathworks, Natick, MA,was USA). calculated and the
of the tungsten electrode tip. The electron temperature of
calculated results were fitted by MATLAB (R2014a, Mathworks, Natick, MA, USA). every position was calculated and the
calculated results were fitted by MATLAB (R2014a, Mathworks, Natick, MA, USA).

Figure1.1.Sketch
Figure Sketchof
of experimental
experimental device.
device.
Figure 1. Sketch of experimental device.
Figure 1. Sketch of experimental device.

Figure 2. Schematic diagram of laser and arc action period.

Figure 2. Schematic diagram of laser and arc action period.
Figure 2. Schematic diagram of laser and arc action period.
Figure 2. Schematic diagram of laser and arc action period.

Figure 3. Spectral lines of arc plasma and the spectral acquisition positions: (a) plasma spectrum of
Figure
hybrid 3. Spectral(b)
welding; lines of arcacquiring
spectral plasma and the spectral
position acquisition positions: (a) plasma spectrum of
on arc plasma.
Figure welding;
hybrid 3. Spectral(b)lines of arcacquiring
spectral plasma and the spectral
position acquisition positions: (a) plasma spectrum of
on arc plasma.
Figure 3. Spectral lines of arc plasma and the spectral acquisition positions: (a) plasma spectrum of
hybrid welding;
The welding;
whole welding(b) spectral
processacquiring
can beposition
divided on arc plasma.
hybrid (b) spectral acquiring position oninto two alternate periods: during laser action and
arc plasma.
afterThe whole
laser action.welding
In thisprocess
study,can thebehigh
divided intocamera
speed two alternate
has a highperiods: during time
resolution laser action
and it andcan
after The whole
laser action.welding
In thisprocess
study, can
the behigh
divided
speedinto two alternate
camera has a periods:
high during time
resolution laser and
actionit and
can
distinguish each picture that is captured during laser action or after laser action. However, for the
Thelaser
after whole
distinguish welding
action.
each picture process
In this study,
that is can thebehigh
captured divided
during into
speed lasertwo
camera alternate
actionhas
or aafterperiods:
high during
resolution
laser action. timelaser
However, action
and it can
for and
the
spectrograph, its resolution time is low and every measurement period includes both during the laser
after laser action.
distinguish
spectrograph, each In this study,
picture that the
is high
captured speed camera
during has
laser a high
action or resolution
after laser time
action. and it can
However, distinguish
for the
action period its and resolution
after the time
laserisaction
low and everySo
period. measurement
the capturedperiod includesisboth
information duringasthe
identified laser
during
each picture
spectrograph,
action thatand
period isresolution
its captured
after the during
time
laser laser
isaction
low andaction or
everySo
period. after laser action.
measurement
the captured period However,
includes
information is for during
both the spectrograph,
identified asthe laser
during
laser action in later descriptions for simplification.
action
its laser period
resolution
action in and
time is after
later low the laser
and every
descriptions foraction period. So
measurement
simplification. the captured
period includesinformation
both during is the
identified as during
laser action period
and laser action
after in later
the laser descriptions
action period. for
So simplification.
the captured information is identified as during laser action in
later descriptions for simplification.
Appl. Sci. 2017, 7, 527 4 of 12
Appl. Sci. 2017, 7, 527 4 of 12

2.2. Materials
Materials and
and Welding
Welding Conditions
Table 1 shows the chemical compositions
compositions of of the
the Ti-6Al-4V.
Ti-6Al-4V. The size of specimen was 10 mm mm
(thickness) ××100
100mm
mm(width)
(width) ××200200mmmm(length),
(length),as
asshown
shownin inFigure
Figure4.4.The
TheVVgroove
groove butt
butt joint
joint with
no
no gap and 1.0 mm root face was used in single TIG welding and laser-TIG welding. The edge was
prepared according conditions by a milling machine. Grease and residue on the base
according to welding conditions base metal
metal
were removed with acetone, and oxidation
oxidation film was removed with emery cloth and stainless stainless steel
brushes before welding. ButtButt joints
joints were
were achieved
achieved inin the
the TIG
TIG welding
welding andand laser-TIG
laser-TIG hybrid
hybrid welding,
welding,
respectively. Weldingconditions
respectively. Welding conditions of of
thethe laser-TIG
laser-TIG hybrid
hybrid welding
welding were shown
were shown in Tablein2.Table 2. After
After welding,
welding, cross-sections
cross-sections were from
were obtained obtained from the transverse
the transverse direction ofdirection
the weldofandthewere
weldpolished,
and wereand polished,
etched
and etched in an acid solution (2 vol % HF + 4 vol % HNO + H O) for the observation
in an acid solution (2 vol % HF + 4 vol % HNO3 + H2 O) for the observation of welding pool size.
3 2 of welding
pool size.
Table 1. Chemical compositions of Ti-6Al-4V (wt %).
Table 1. Chemical compositions of Ti-6Al-4V (wt %).
Elements Al V Fe C N O Ti
Elements Al V Fe C N O Ti
Wt.% 5.50~6.75 3.50~4.50 0.30 0.08 0.05 0.20 residual
Wt.% 5.50~6.75 3.50~4.50 0.30 0.08 0.05 0.20 residual

Figure 4. The size of specimen and groove shape.

Figure 4. The size of specimen and groove shape.

Table 2. Welding parameters of laser-arc hybrid welding processes.

Table 2. Welding parameters of laser-arc hybrid welding processes.
Laser-TIG Hybrid Welding
Parameters Value of Single TIG
Laser-TIG
Value Laser HybridValue
Welding TIG
Parameters Value of Single TIG
Power source type DC Value Pulse
Laser DCTIG
Value
Electrode
Power source typetype W-2%
DC ThO2 Pulse - W-2% DCThO2
Diameter of electrode,
Electrode type (mm) W-2% ThO3.22 - - W-2%3.2ThO2
Diameter
Angleofofelectrode,
electrode(mm) (θ), ° 3.2 45 - 90 3.2
45
Angle of electrode (θ), ◦ 45 90 45
Welding current (I), A 260, 300 - 200
Welding current (I), A 260, 300 - 200
Laserpulse
Laser pulse energy
energy (Q),(Q),J J - - 20 20 --
Laserpulse
Laser pulse frequency
frequency (f ), (f)
HzHz, - - 20 20 --
Dla, (mm)
Dla, (mm) - - 2,2,3.5
3.5
Shielding
Shielding gasgastype type PurePure
Ar Ar - - Pure Ar
Pure Ar
Gas flow rate (q), L/min 15 - 15
Gas flow rate (q), L/min 15 - 15
Arc length (l), mm 4 - 4
WeldingArc length
speed (v), (l),
mm/minmm 400 4 400 - 4
400
Welding speed (v), mm/min 400 400 400
3. Results and Discussion
3. Results and Discussion
3.1. Back Appearance and Cross Section of Weld Bead
3.1. Back Appearance and Cross Section of Weld Bead
Figure 5 shows the back surface and cross section of a weld seam of single TIG and hybrid welding.
FromFigure
Figure55a,
shows
it can the back surface
be found and cross
that the back section
surface of the of a weld
weld seam seam of single
produced TIGTIG
by single andwelding,
hybrid
welding. From Figure 5a, it can be found that the back surface of the weld seam
presents incomplete fusion. The heat input is 390 J/mm. If the welding current is increased, produced by single
and
TIG
otherwelding, presents
parameters remainincomplete
constant, thefusion.
burn The heaton
through input is 390
the back J/mm.
of the If penetration
weld the weldingcan current is
be seen,
increased, and other parameters remain constant, the burn through on the
as shown in Figure 5b. The heat input is about 448 J/mm. During the laser-TIG welding process,back of the weld
penetration can be seen, as shown in Figure 5b. The heat input is about 448 J/mm. During the laser-
TIG welding process, adjusting the Dla, welding current of TIG, laser pulse energy, a sound fusion
Appl. Sci. 2017, 7, 527 5 of 12

adjusting the Dla, welding current of TIG, laser pulse energy, a sound fusion shape in butt welding
Appl. Sci. 2017, 7, 527
of a thick plate root layer can be realized under a group of certain condition: Q = 20 J, f5 = of 12
20 Hz,
I = 200 A, v = 400 mm/min, Dla = 2 mm, as presented in Figure 5c. The heat input of hybrid welding
shape in butt welding of a thick plate root layer can be realized under a group of certain condition:
is about
Q = 358
20 J,J/mm.
f = 20 Hz, SeenI = from
200 A,the
v = transverse
400 mm/min, section
Dla = 2ofmm,hybrid welding,initFigure
as presented is found thatheat
5c. The bothinput
sides are
fusionof hybrid welding is about 358 J/mm. Seen from the transverse section of hybrid welding, it is found 5d
sound. The back weld width 2 mm and root reinforcement 0.4 mm are moderate. Figure
Appl. Sci. 2017, 7, 527 5 of 12
presents
that the
bothweld sidesappearance of theThe
are fusion sound. hybrid
back weld samples
weld width 2 mm underand the
rootcondition
reinforcementof Dla0.4 3.5
mmmm, are and
othermoderate.
conditions Figure 5d presents the weld appearance of the hybrid weld samples
Dla under
shape in butt welding of a thick plate root layer can be realized under a group of certain condition: back
are same as in Figure 5c. It is found that with the increase to the
3.5 condition
mm, the
of
weld willDla 3.5
20 J,mm,
Q =present f = an
20andHz, other conditions
I = 200
undercut A, are
v = 400This
defect. same
mm/min,
means asDla
in =Figure
that2 the 5c. It is found
mm,addition
as presented inthat
of pulse with
Figure the
5c.
laser Dla
The
can increase
heat
promote inputthe to heat
3.5 mm,
of the
hybrid back
welding weldis will
about present
358 J/mm.an undercut
Seen from defect.
the This
transverse means
section that
of the
hybrid
transfer to the depth of the penetration, and Dla plays an important role in the heat distribution of the addition
welding, ofit pulse
is foundlaser
canthat
promote the heat transfer to theThe
depth of weld
the penetration,
sound and and
both sides are fusion sound. back width 2 mm andDla rootplays an important
reinforcement 0.4 mmrole in
arethe
pool in the laser-TIG hybrid welding process. The uniformed formation of the bottom can
heatmoderate.
distributionFigure of5dthepresents
pool inthe weld
the appearance
laser-TIG hybrid of the hybridprocess.
welding weld samples under and
The sound the condition
uniformed
be realized by hybrid
of Dla 3.5ofmm,
welding processare because the laser 5c.
makes appropriate heatDladistribution in the
formation theand other conditions
bottom can be realized samebyas hybrid
in Figurewelding It is found
processthatbecause
with the the increase
laser makes to
molten pool.
3.5 mm, the
appropriate heatback weld will present
distribution an undercut
in the molten pool. defect. This means that the addition of pulse laser
can promote the heat transfer to the depth of the penetration, and Dla plays an important role in the
heat distribution of the pool in the laser-TIG hybrid welding process. The sound and uniformed
formation of the bottom can be realized by hybrid welding process because the laser makes
appropriate heat distribution in the molten pool.

Figure 5. Back
Figure surface
5. Back and
surface cross
and section
cross sectionof
ofweld
weld seam withsingle
seam with singletungsten
tungsten inert
inert gasgas (TIG)
(TIG) and hybrid
and hybrid
welding: (a) single TIG; (b) single TIG; (c) hybrid welding; (d) hybrid welding.
welding: (a) single TIG; (b) single TIG; (c) hybrid welding; (d) hybrid welding.

After welding,
Figure the optical
5. Back surface microstructure
and cross ofseam
section of weld the fusion zoon
with single (FZ) and
tungsten inertheat affected
gas (TIG) zoon (HAZ)
and hybrid
After
with thewelding,
welding: (a)the
parameters optical
ofTIG;
single Figuremicrostructure
(b) 5c are
single TIG;adopted oftothe
(c) hybrid fusion
carry
welding; out zoon (FZ) and
the analysis,
(d) hybrid welding. as heat
shown affected zoon
in Figure (HAZ)
6a,b
with respectively.
the parameters Due to of Figure
the 5c
difference are adopted
of the coolingtoratecarry out
in the FZthe andanalysis,
HAZ, theirasweld
After welding, the optical microstructure of the fusion zoon (FZ) and heat affected zoon (HAZ)
shown in Figure
microstructure 6a,b
presents
respectively. different
Due to morphology.
the difference Because
of the of the
cooling slower
rate cooling
in the FZ in
andFZ, a number
HAZ,
with the parameters of Figure 5c are adopted to carry out the analysis, as shown in Figure 6a,b theirof bulky
weld columnar
microstructure
crystals
presents with the
different
respectively. acicular
to the phase
morphology.
Due α’ phase
Because
difference and
of theof thesmall
cooling amount
slower
rate of and
cooling
in the FZ theinprimary β phase
FZ, atheir
HAZ, number increased
of bulkyin
weld microstructure FZ,
columnar
as shown
crystals presentsin Figure
with thedifferent 6a. Due
acicularmorphology. to the
phase α’ phase fast
Becausecooling
and in
of small HAZ,
the slower
amount the globular
cooling in FZ,
of the phase with
a number
primary the mixed
of bulky
β phase columnarinofFZ, as
pattern
increased
thecrystals
acicularwith
martensite and the primary α phase appeared in the HAZ, as shown in Figure 6b.
shown in Figure 6a.the Dueacicular
to thephase
fast α’ phase and
cooling small amount
in HAZ, of the primary
the globular phase withβ phase
theincreased in FZ, of the
mixed pattern
as shown in Figure 6a. Due to the fast cooling in HAZ, the globular phase with the mixed pattern of
acicular martensite and the primary α phase appeared in the HAZ, as shown in Figure 6b.
the acicular martensite and the primary α phase appeared in the HAZ, as shown in Figure 6b.

Figure 6. Optical microstructure of weld: (a) fusion zoon (FZ); (b) heat affected zoon (HAZ).

Figure 6. Optical microstructure of weld: (a) fusion zoon (FZ); (b) heat affected zoon (HAZ).
Figure 6. Optical microstructure of weld: (a) fusion zoon (FZ); (b) heat affected zoon (HAZ).
Appl. Sci. 2017, 7, 527 6 of 12

3.2. Arc Behaviors Observation

3.2. Arc Behaviors Observation
In order to facilitate the observation, bead-on-plate welding experiments were carried out. To
In order
detail the to facilitate
comparisons thestate,
of arc observation, bead-on-plate
the arc behaviors welding
from a side viewexperiments
were captured were
by acarried out.
high speed
To detail the comparisons of arc state, the arc behaviors from a side view were
camera. Figure 7 shows the arc behaviors in single TIG and hybrid welding with the Dla 2 mm, captured by a high
speed camera.The
respectively. Figure 7 shows
welding the arc behaviors
parameters are listedininsingle
Table TIG
2. Asand hybrid welding
illustrated in Figurewith the Dla
7, due to the2 mm,
DC
respectively. The welding parameters are listed in Table 2. As illustrated in Figure
current being employed in this experiment, in single TIG welding the arc always discharges stably 7, due to the DC
current
along thebeing employed
tungsten in this
extension. experiment,
However, in is
the arc single TIG welding
compressed the with
cyclically arc always discharges
the pulse stably
laser in hybrid
along the In
welding. tungsten extension.
comparison with However,
single TIGthe arc is compressed
welding, cyclically
the 4 mm distance with the
between pulse
the laser
tip of the in hybrid
tungsten
welding. In comparison with single TIG welding, the 4 mm distance between the tip
and discharge position, is reduced to 2 mm with laser action. This quantitative description proves of the tungsten
and
that discharge
with the position,
action ofis laser
reduced to 2 mm
pulses, the with
arc laser action.
will act This quantitative
at different description
locations provespool
of the molten that
with the action of laser pulses, the arc will act at different locations of the molten pool periodically.
periodically.

Figure 7. Arc behaviors in different welding process: (a) single TIG; (b) hybrid welding.
Figure 7. Arc behaviors in different welding process: (a) single TIG; (b) hybrid welding.

The electronic temperature, which is considered as a main metric of the average kinetic energy
of theThe electronic temperature,
mico-particles in the plasma, whichis anisimportant
consideredmeasurement
as a main metric of thethe
to study average
heat and kinetic
massenergy of
transfer
the mico-particles in the plasma, is an important measurement to study the
of plasma, and it also reflects the spatial distribution of the arc state from the other side [19]. Figureheat and mass transfer of
plasma,
8 shows and it alsodifference
the major reflects the ofspatial distribution
distribution of the arc temperature
of the electronic state from the other side
between TIG[19]. Figure
welding and 8
shows the major difference of distribution of the electronic temperature
hybrid welding. The result shows that the distribution of electronic temperature presents the between TIG welding and
hybrid welding.
dispersing state The
in TIG result shows but
welding, thatthethecompressing
distribution of electronic
state temperature
in hybrid welding.presents the dispersing
In the hybrid welding
state in TIG welding, but the compressing state in hybrid welding.
process, although the electronic temperature near the region where laser acts is decreased, the In the hybrid welding process,
high
although the electronic temperature near the region where laser acts is
temperature region is compressed directly above the laser keyhole. Compared with TIG welding, thedecreased, the high temperature
region is compressed
axis of high temperature directly
regionabove
in thethe laser welding
hybrid keyhole.process
Compared withfrom
changes TIG welding,
a straightthe lineaxis
to aofcurve.
high
temperature region in the hybrid welding process changes from a
In the hybrid welding process, the plasma is located above the laser action point vertically and straight line to a curve. In the
hybrid welding process, the plasma is located above the laser action
connects to the electrode obliquely. This phenomenon is also shown in Figure 9. The electronic point vertically and connects
to the electrode
temperature obliquely.
decreases fromThis phenomenon
the tungsten is also
electrode to shown in Figure
the workpiece 9. The
in the TIGelectronic temperature
welding process while
decreases
it decreases firstly and then increases again from tungsten electrode tip to laser action itspot
from the tungsten electrode to the workpiece in the TIG welding process while decreases
in the
firstly
hybridand then increases
welding process. The again from tungsten
addition electrode
of the laser is the tip
mainto laser
factoraction
whichspot in the
causes hybrid
this change welding
of the
process. The addition of the laser is the main factor which causes
distribution of the electronic temperature in hybrid welding process. When the laser is added, this change of the distribution of
the electronic temperature in hybrid welding process. When the laser is
titanium is vaporized rapidly with low ionization energy, Ti atoms are ionized and thus plasma with added, titanium is vaporized
rapidly with low
recoil pressure is ionization
formed. The energy,
recoilTipressure
atoms are ionized
causes the and
laserthus plasma
induced with recoil
plasma to be pressure
distributed is
formed. The recoil pressure causes the laser induced plasma to be distributed
vertically above the laser keyhole. The titanium atoms are cumulatively ionized due to the collision vertically above the laser
keyhole. The titanium
with high-energy atomsThe
electrons. are cumulatively
laser keyholeionized due to
will supply the collision
plenty with for
of electrons high-energy
arc plasma, electrons.
so the
The laser keyhole will
conducting route changes. supply plenty of electrons for arc plasma, so the conducting route changes.
Appl. Sci. 2017, 7, 527 7 of 12
Appl. Sci. 2017, 7, 527 7 of 12
Appl. Sci. 2017, 7, 527 7 of 12

Figure 8. Distribution of plasma temperature in different welding process: (a) single TIG; (b) hybrid
Figure 8. Distribution of plasma temperature in different welding process: (a) single TIG;
Figure 8. Distribution of plasma temperature in different welding process: (a) single TIG; (b) hybrid
welding.
(b) hybrid welding.
welding.

Figure 9. Melting pool behaviors in different welding process: (a) single TIG; (b) hybrid welding.
Figure 9. Melting pool behaviors in different welding process: (a) single TIG; (b) hybrid welding.
Figure 9. Melting pool behaviors in different welding process: (a) single TIG; (b) hybrid welding.
4. Discussion
4. Discussion
4. Discussion
4.1. Arc Deflection
4.1. Arc Deflection
4.1. Arc
TheDeflection
arc deflection is determined by electromagnetic force between the TIG arc and the laser
The plasma.
induced arc deflection
As noted is determined bywritten
in the paperby electromagnetic forcewhen
by Chen [20], between the TIG
the laser arc
actsarc and
on and the laser
a workpiece,
The arc deflection is determined electromagnetic force between the TIG the laser
induced
there plasma.
are plasma. As noted
two currents with thein the
samepaper written
direction by Chen
between the [20], when thethe
electrode laser acts on aAworkpiece,
induced As noted in the paper written by Chen [20], whenand workpiece.
the laser simplified
acts on a workpiece,
there are
modelare two currents
is established with the same direction between the electrode and the workpiece. A simplified
there two currentstowith
calculate the deflected
the same length. Figure
direction between 10 shows
the electrode anda schematic illustration
the workpiece. of the
A simplified
model
arc is established
attraction between to calculate
the laser the
and deflected
arc. In length.
this case, Figure
the TIG 10
arcshows
is a schematic
attracted and illustration
repulsed of the
outwards
model is established to calculate the deflected length. Figure 10 shows a schematic illustration of the
arc attraction
because between
of thebetween the laser and arc. In this case, the TIG arc is attracted and repulsed outwards
electromagnetic
arc attraction the laserforces.
and arc. In this case, the TIG arc is attracted and repulsed outwards
because of the electromagnetic forces.
because of the electromagnetic forces.
Generally speaking, the deflected length d can be expressed by the following Formula (1) [21],

h2 I L
d= cos θ (1)
2Ia DLM

where d is the deflected length for the pulsed TIG arc, h is the length for the TIG arc, IL is the
current in the keyhole, Ia is the TIG arc current and DLM the arc distance. However, in this paper
the arc is expected to be completely attracted to the laser keyhole, so DLM = d = Dla = 2 mm, thus the
formula becomes
Appl. Sci. 2017, 7, 527 8 of 12

s
h2 I L
d= cos θ (2)
2Ia
Figure 10. Schematic illustration of arc attraction between laser and arc.
Therefore, the required minimum keyhole current, that can provide enough energy to attract the
arc rootGenerally
to the laser action point,
speaking, is calculated
the deflected lengthto dbecan142beA.expressed by the following Formula (1) [21],
Figure 11 shows a comparison of the required keyhole current calculated for different deflected
lengths at an arc current of 100, 200 and 300 A. h 2 IItL can be seen that in the case of a certain arc current,
d= cos θ (1)
with the increase of the deflected length, the 2I required
D keyhole current increases. For the same deflected
a LM
length, the required keyhole current increases with the increase of the arc current. Besides, as the
deflected
where
Appl. dlength
is 7,the
Sci. 2017, increases,length
527deflected the larger the pulsed
for the arc current
TIG is, the
arc, greater
h is the keyhole
the length for the current
TIG arc,must be. current
IL is the 8 of 12
in the keyhole, Ia is the TIG arc current and DLM the arc distance. However, in this paper the arc is
expected to be completely attracted to the laser keyhole, so DLM= d = Dla = 2 mm, thus the formula
becomes

h2I L
d= cos θ (2)
2I a

Therefore, the required minimum keyhole current, that can provide enough energy to attract the
arc root to the laser action point, is calculated to be 142 A.
Figure 11 shows a comparison of the required keyhole current calculated for different deflected
lengths at an arc current of 100, 200 and 300 A. It can be seen that in the case of a certain arc current,
with the increase of the deflected length, the required keyhole current increases. For the same
deflected length, the required keyhole current increases with the increase of the arc current. Besides,
as the deflected length increases, the larger the arc current is, the greater the keyhole current must
be. Figure 10. Schematic illustration of arc attraction between laser and arc.
Figure 10. Schematic illustration of arc attraction between laser and arc.

Generally speaking, the deflected length d can be expressed by the following Formula (1) [21],

h2I L
d= cos θ (1)
2I a DLM

where d is the deflected length for the pulsed TIG arc, h is the length for the TIG arc, IL is the current
in the keyhole, Ia is the TIG arc current and DLM the arc distance. However, in this paper the arc is
expected to be completely attracted to the laser keyhole, so DLM= d = Dla = 2 mm, thus the formula
becomes

h2I
L
Figure
Figure 11.11. Relationship
Relationship d = required
between
between coskeyhole
requiredθkeyholecurrent
current and
and deflected
deflected length.
length. (2)
2I a
In addition, the current IL’ in the keyhole can be given by Ohm’s law [22].
In addition, the current IL 0 in the keyhole can be given by Ohm’s law [22].
Therefore, the required minimum keyhole current, that can provide enough energy to attract the
arc root to the laser action point, is calculated to ZRbe 142 A.
Figure 11 shows a comparison of the
0 required
IL = 2πE σrdr keyhole
= πR2current
σE calculated for different deflected
(3)
lengths at an arc current of 100, 200 and 300 A.0It can be seen that in the case of a certain arc current,
with the increase of the deflected length, the required keyhole current increases. For the same
and the specific
deflected length,electrical conductivity
the required keyhole of the laser
current induced
increases plasma
with in the keyhole
the increase σ iscurrent.
of the arc given byBesides,
as the deflected length increases, the larger the arc current is, the greater the keyhole current must
3 (kTe )
be. σ= √ (4)
4 2πme λe e2

where E is the axial component of the electric field intensity in the keyhole, σ is the specific electrical
conductivity of the laser induced plasma in the keyhole, R is the radius of the current conducting
 3 ( kTe )
(4)
4 2 me e e 2

where E is the axial component of the electric field intensity in the keyhole, σ is the specific electrical
Appl. Sci. 2017, 7, 527 9 of 12
conductivity of the laser induced plasma in the keyhole, R is the radius of the current conducting
region. R is considered as the approximate radius of keyhole, when the keyhole is assumed to be a
cylinder.R kis isconsidered
region. the Boltzmann constant, 𝑇𝑒 radius
as the approximate is the of keyhole,temperature
electronic when the keyhole 𝑚𝑒 istothe
is assumed
in keyhole, be
aelectronic k is the
cylinder. mass, Boltzmann constant,
λe is the free path and e isT is the electronic
e the electron charge. temperature in keyhole, m e is the electronic
mass,Inλethisis the free path and
experiment, the evalues
is the electron
of λe, Techarge.
and E are approximately 0.75 mm, 15,000 K (usually
In this
keyhole experiment,
electron the values
temperature is higher e , Tethat
of λthan andinE arc)
are approximately 0.75 mm, 15,000
and 3 V/mm, respectively. K (usually
Therefore, σ can
be approximately estimated to be 1.2 × 10 S/m, and the instantaneous current of keyhole ⃗⃗⃗𝐼𝐿 is about
keyhole electron temperature is higher than 4 that in arc) and 3 V/mm, respectively. Therefore, σ can be
→
103 A. It is obvious
approximately that IL’≥I
estimated meaning
toLbe 1.2 × 10 4 S/m,
that in this andpart
theofinstantaneous
experiment the arc is of
current easily attracted
keyhole IL is by
aboutthe
10 3
laserA.induced plasma
It is obvious that 0
produced by a pulsethat
IL ≥ IL meaning laser.in this part of experiment the arc is easily attracted by
the laser induced plasma produced by a pulse laser.
4.2. Analysis of Forces on Back Molten Pool
4.2. Analysis of Forces on Back Molten Pool
The shape, dimension and the volume of the molten pool have significant influence on the weld
shapeThe shape,
in the dimension
welding process,andespecially
the volume of the
in root molten In
welding. pool have significant
one-side welding withinfluence on the weld
back formation in
shape in the welding process, especially in root welding. In one-side welding
the root welding process, the metal is melted into the molten pool and then frozen into welds. There with back formation
in
arethe root welding
several mechanisms process,
that the metal is
influence the melted
stabilityintoofthe
themolten
moltenpool
pooland thenwelding
in the frozen into welds.
process as
There
sketchedare in
several
Figuremechanisms thatcombined
12. First, in the influence effectthe stability of the molten
of arc pressure, pool in the
gravitational welding
force, surfaceprocess
tension, as
sketched
adhesive in Figure
force 12. First,
between the in the combined
molten pool andeffect frontofbase
arc pressure,
metal or gravitational force, surface
back solidification weld, thetension,
back
adhesive
liquid metal force between
hangs in thethe molten
space. The pool
last two andforces
front are
basethemetal or back
function solidification
of temperature. weld, thetoback
According the
liquid metal hangs in the space. The last two forces are the function of temperature.
Formula (5), only when the four forces coordinate with each other and balances can the molten pool According to the
Formula (5), only
keep stability [23].when the four forces coordinate with each other and balances can the molten pool
keep stability [23].
F Fσ F+ Fδ = FmFm + FAFsin θ
A sin θ
(5)
(5)

where FFσσ is the

where the surface tension,FFδ δisisthe
surfacetension, theadhesive
adhesiveforce, FmFmis is
force, the gravity,
the FA FisA the
gravity, arcarc
is the pressure, θ isθthe
pressure, is
angle of electrode.
the angle of electrode.

Figure
Figure 12.
12. Schematic
Schematic diagram
diagram of
of the
the forces acts on
forces acts on back
back molten
molten pool.
pool.

However, according to present research, surface tension and adhesive force are a function of
temperature. Therefore, the higher the temperature is, the lower the surface tension and adhesive
force. Uneven temperature distribution will inevitably lead to uneven surface tension and adhesive
force distribution. The gravity determined by the dimension of the molten pool is also affected
by temperature. The higher the temperature, the larger the dimension of the molten pool will get.
The temperature of the molten pool is proportional to gravity and inversely proportional to the surface
tension and adhesive force. Meanwhile, due to the top and back of the molten pool always being
interconnected in the welding process, the arc passes through the molten pool and acts on the back
molten pool directly. So it is important to control the shape of the back molten pool by adjusting the
Appl. Sci. 2017, 7, 527 10 of 12

temperature distribution over the top of the molten pool. According to manual arc welding for one
side welding with back formation, the arc distribution on the molten pool front rim plays a decisive
role in weld bead formation on the back side [24–27].

4.3. The Effect of Pulsed Laser in Welding Process

In this research, during pulsed laser-arc welding, the state of the melting pool is closely related to
the periodical behavior of the liquid metal. Figure 13 shows the relative location of the arc and the
molten pool in different welding processes. As illustrated in Figure 13a, during single TIG welding,
because of the arc stiffness caused by the high-power jet from the tungsten electrode, the arc always
completely covers the molten pool and arc force acts on the surface of the molten pool along the
extension of the tungsten electrode. Due to lower energy density of single TIG welding, the incomplete
penetration may be caused with higher linear energy. However, a small increase in linear energy
requires an increase in arc current. According to Formula (6), the arc pressure is proportional to the
square of the currents, so the increase of current will result in the increase of arc pressure, arc stiffness
and size of the molten pool, ultimately causing the weld to be burnt through [28,29].

µ I2
F= × a 2 ( R2 − r 2 ) (6)
4π πR
where Ia is the arc current, µ is the arc magnetic permittivity, F is the arc static pressure, R is the radius
of the arc, r is the distance from arbitrary points to the axial of arc.
Appl. Sci. 2017, 7, 527 11 of 12

Figure 13.
Figure 13. Schematic diagram
Schematic of molten
diagram pool in
of molten different
pool weldingwelding
in different process: process:
(a) single (a)
TIG;single
(b) hybrid
TIG;
welding.
(b) hybrid welding.

5. Conclusions
A balance state of four-balance forces (surface tension, arc force, gravity and adhesive force)
According
is difficult to the with
to achieve results and analysis,
liquid titanium the following
alloys conclusions
with lower can be achieved.
and changeable surface tension at the
Thepoint.
melting addition of abepulse
It can found laser
thatcan
TIGpromote
weldingthe heat
with transfer
single typedownward along theispenetration,
and poor tolerance difficult to
and compared
control with single
in the welding TIG welding, a sound and uniformed formation of the bottom can be
process.
realized with
Figure lower
13b heat input
presents in the rootdiagram
the schematic hybrid welding
of the arcprocess.
and molten pool in hybrid welding, in
In root hybrid
comparison welding,
with Figure 13a, the attraction
it can be seenforce of the
that the laser pool
molten induced
alongplasma on the TIG
the welding arc plays
direction can bean
important role in the arc distribution over the top molten pool surface, and this
divided into front molten pool area I named the hybrid heat source action area and rear molten pool influences the weld
beadIIformation
area named the onarc
theaction
back area,
side. and
Underthisthe condition
differs that welding
from TIG the arc alternates
in which abetween the enhanced
single molten pool is
state andThis
formed. the original
is mainlystate, the balance
because of force
the original arcand heat is reached,
is attracted and the stable
and enhanced molten
by laser is achieved.
induced plasma
during laser action, and the arc column is compressed, deflected and attracted to the laser action point
Acknowledgment:
over the top of theThe authors
molten gratefully
pool. acknowledge
Meanwhile, the sponsorship
in the case from density
of high energy Natural gradient,
Science Foundation
arc energy of
China (No. 11375038), Science Fund for Creative Research Groups of NSFC (No. 51621064).
is transferred along the direction of penetration. After laser action, the arc restores to its original
state
Authorwith low energy Jipeng
Contributions: densityShi,
andLiming
acts onLiutheand
molten
Yanbinpool. Under
Zhou the action
conceived, of theand
designed pulsed laser, the
performed the
experiments. Jipeng Shi and Liming Liu analyzed the data. All authors contributed to the preparation of the
manuscript.

Conflicts of Interest: The authors declare no conflict of interest.

References
Appl. Sci. 2017, 7, 527 11 of 12

enhanced arc alternates as the original arc acts on the pool area I and II, respectively. When the laser
acts on area I, metal in area I is melted forming a molten pool. However, without arc action, the bottom
of the molten pool in area II would solidify into a weld seam due to a very large amount of heat being
taken away from the molten pool by shielding gas. After laser action, the molten pool is completely
covered by a low energy density arc and the arc heat is not enough to fully melt the bottom of the
weld seam into molten pool, so the bottom of the molten pool is still solid. In this case, the top of
the liquid metal will be held by the bottom weld seam. Meanwhile, the length of the molten pool is
shortened along the welding direction. In this situation, the four forces make it easy to achieve balance
and a stable molten pool is obtained.

5. Conclusions
According to the results and analysis, the following conclusions can be achieved.
The addition of a pulse laser can promote the heat transfer downward along the penetration, and
compared with single TIG welding, a sound and uniformed formation of the bottom can be realized
with lower heat input in the root hybrid welding process.
In root hybrid welding, the attraction force of the laser induced plasma on the TIG arc plays
an important role in the arc distribution over the top molten pool surface, and this influences the weld
bead formation on the back side. Under the condition that the arc alternates between the enhanced
state and the original state, the balance of force and heat is reached, and the stable molten is achieved.

Acknowledgments: The authors gratefully acknowledge the sponsorship from Natural Science Foundation of
China (No. 11375038), Science Fund for Creative Research Groups of NSFC (No. 51621064).
Author Contributions: Jipeng Shi, Liming Liu and Yanbin Zhou conceived, designed and performed the
experiments. Jipeng Shi and Liming Liu analyzed the data. All authors contributed to the preparation of
the manuscript.
Conflicts of Interest: The authors declare no conflict of interest.

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