Detection of defects in laser welding of AZ31B magnesium alloy in zero-gap lap joint configuration by a real-time spectroscopic analysis

• The dynamics behavior of the molten pool of samples with two surface conditions is monitored in real-time during laser welding using a CCD camera.
• The absorption of laser power increases with the presence of oxide at the faying surface resulting in a larger and deeper weld bead.
• The spectrum intensity of laser induced plasma plume is detected by spectrometer and Beam view CCD camera.
• There is a good correlation between calculated electron temperature and the weld porosity.

The effect of surface oxide layer existing at the lap-joint faying surface of magnesium sheets is investigated on the keyhole dynamics of the weld pool and weld bead qualities. It is observed that by removing the oxide layer from the faying surface of the lap joint, a high quality weld can be achieved in the laser welding process. However, the presence of an oxide layer deteriorates the quality of the weld by forming pores at the interface of the two overlapped sheets. The purpose of this paper is to identify the correlation between the integrity of the weld and the interaction between the laser and material. A spectroscopy sensor was applied to detect the spectra emitted from a plasma plume during the laser welding of AZ31B magnesium alloy in a zero-gap lap joint configuration. The electron temperature was calculated by applying a Boltzmann plot method based on the detected spectra, and the correlation between the pore formation and the spectral signals was studied. The laser molten pool and the keyhole condition were monitored in real-time by a high speed charge-coupled device (CCD) camera. A green laser was used as an illumination source in order to detect the influence of the oxide layer on the dynamic behavior of the molten pool. Results revealed that the detected spectrum and weld defects had a meaningful correlation for real-time monitoring of the weld quality during laser welding of magnesium alloys.