Effects of solidification on flow dynamics: A novel comprehension of defects formation in laser penetration welding

The laser penetration welding for medium-thickness plates struggles with unstable molten pool behavior and a limited processing window, often leading to welding defects including spatters, depressions, and especially humps. In this study, forming processes of the defects were observed by using a high-speed camera, and forming mechanism of the defects were then analyzed in detail by simultaneously considering the influences of force and solidification. It was clear that the mass loss caused by spattering during the heating phase contributed to the depression, which was consistent with the existing knowledge. However, the formation mechanism of humps concluded in this study was different to the present understanding. Apart from the influences of force, the effects of solidification on molten pools and humps were analyzed. Under the specific conditions, middle part of molten pool solidified rapidly, causing localized necking, and disrupting the circular flow of the molten metal. As a result, molten metal once flowed downward due to the gravity and temperature can no longer refill to the upper part again, leading to the accumulation of molten metal at lower part and ultimately the formation of humps. These findings offered a fresh perspective on the formation of hump, provided valuable guidance for enhancing the quality and efficiency of thick-plate laser welding.