Experimental and theoretical characterization of deep penetration welding threshold induced by 1-μm laser

Abstract The deep penetration-welding threshold (DPWT) is the critical value that describes the welding mode transition from the thermal conduction to the deep penetration. The objective of this research is to clarify the DPWT induced by the lasers with wavelength of 1 μm (1-μm laser), based on experimental observation and theoretical analysis. The experimental results indicated that the DPWT was the ratio between laser power and laser spot diameter ( P / d ) rather than laser power density ( P / S ). The evaporation threshold was smaller than the DPWT, while the jump threshold of the evaporated mass flux in the molten pool surface was consistent with the DPWT. Based on the force balance between the evaporation recoil pressure and the surface tension pressure at the gas–liquid interface of the molten pool as well as the temperature field, we developed a self-focusing model, which further confirmed the experimental results.