A three-dimensional model of multiple reflections for high-speed deep penetration laser welding based on an actual keyhole

Keyhole shapes are observed experimentally by two high-speed cameras from two perpendicular directions in high-speed laser welding of glass. From the obtained keyhole pictures, it can be seen that in high-speed deep penetration laser welding, the keyhole is not only seriously bent in the direction opposite to that of welding speed, but also elongated along the direction of the welding speed. Based on the so-obtained keyhole photograph, the keyhole profiles in both the symmetric plane and its perpendicular plane (i.e., the cross-section plane) are determined by the method of polynomial fitting. Then, under the assumption of elliptical cross-section of the keyhole at each keyhole depth, a 3D bending keyhole is reconstructed, the behavior of focused Gaussian laser beam in the keyhole is analyzed by tracing a ray of light using geometrical optics theory. Fresnel absorption and multiple reflections in the keyhole are systematically studied, and the laser intensities absorbed on the keyhole walls are calculated. In determining the distribution of laser intensity on the keyhole wall, the bending of the keyhole plays the dominant role, elongation of the keyhole plays just a minor role. Because of the bending of the keyhole, not all the keyhole wall can be irradiated directly by laser beam. The absorbed laser intensity cannot be uniformly distributed on the keyhole wall even after multiple reflections. The keyhole wall absorbs laser intensity mainly on the small area near the front keyhole wall. Recoil pressure plays a dominant role in forming a keyhole and keeping it open.