A novel “sandwich” method for observation of the keyhole in deep penetration laser welding

A sandwich method was used to observe the keyhole in deep penetration laser welding, which provided an effective way to analyze both the Fresnel and inverse Bremsstrahlung absorption. In the transparent metal-analog system, different densities of metal vapor, ionized atoms, and free electrons in the keyhole can be simulated by changing the thickness of aluminum films. The research results show that inverse Bremsstrahlung absorption exerts a tremendous influence on the energy absorption of the laser beam for CO2 laser welding. Low density of keyhole plasma benefits the incident laser energy coupling to the materials. However, excess density of keyhole plasma baffles the transmission of the incident laser beam to the interior material. By comparing inflow energy and outflow energy, there exits an energy balance on the keyhole wall by balancing the absorbed laser intensity and heat flux on the wall.