Effect of keyhole geometry and dynamics in zero-gap laser welding of zinc-coated steel sheets

Both zinc-coated and uncoated DP 590 steel sheets were used for laser welding experiment with a 2 kW multi-mode fiber laser under the same experimental conditions. Using systematically obtained keyhole data, how the keyhole dynamically responds to an incident laser beam was studied by defining several key factors, such as keyhole expansion factor, keyhole motion range factor, average aperture diameters, mass loss fraction and melt pool volume size. The relative configuration of the keyhole and the laser beam was found to be the most influential factor for obtaining good welds, and when the beam was located away from the front keyhole wall a good weld was obtained. When the beam irradiates on the front keyhole wall, the zinc evaporation region between the two sheets can be directly heated by the beam, and the zinc vapor pressure can become extremely large, and therefore the melt pool is severely disturbed. The keyhole bottom aperture diameter and the keyhole expansion factor for the bottom aperture were both largely proportional to the mass loss for both zinc-coated and uncoated steels. Zero-gap laser welding of zinc-coated steels can be indeed successful and a theoretical basis is presented.