Influence of environmental pressure on the energy coupling and droplet transition behavior in laser welding with filler wire

The influence of environmental pressure on droplet behavior and weld formation in laser welding with filler wire for 304 stainless steel was investigated and the energy coupling behavior was analyzed. As ambient pressure increases from 5 kPa to 700 kPa, the weld depth decreases by 77 %, the variance of the weld width increases approximately 5 times, and the continuity of the weld surface formation deteriorates. During the welding process, a high-speed camera was employed to observe the melt pool, plasma, and melt drop transition behavior. With an increase in the ambient pressure followed by an increase in the metal evaporation temperature, the effects of shielding of the plasma and its internal metal vapor particles on the laser beam lead to a reduction in the depth of the melt. The inverse bremsstrahlung absorption of laser by plasma increased by approximately 36.3 times at 700 kPa compared with that at atmospheric pressure. The number of metal vapor particles at 700 kPa is approximately 3.58 times higher than that at 101 kPa, and the average particle diameter is approximately 0.4 times higher, causing enhanced absorption of laser light by the metal vapor particles. An increase in gas density at elevated ambient pressures resulted in a significant increase in the resistance to droplet descent and decrease in the drive force, leading to an increase in the droplet transition period. This change shifts from a liquid bridge transition to a particle transition, which is the main cause of the deterioration of weld surface formation at high pressures.