Characterization of keyhole dynamics in laser welding of copper by means of high-speed synchrotron X-ray imaging

Laser welding of copper is of great importance for industrial applications, e.g., for manufacturing of electrical components such as hairpins. Solid state lasers are widely used due to the high power and beam brilliance, but the implementation can be challenging in terms of process instabilities and resulting weld defects, i.e., spatter and pore formation. In order to understand the formation thus avoid these defects, the development of the understanding of the keyhole and its interaction with the surrounding melt pool is required. In this paper, high-speed synchrotron X-ray imaging (frame rate: 20,000 Hz) demonstrated its capability to study the keyhole geometry to quantify and describe the dynamic behavior inside the workpiece. Thus, novel insights into fundamental processes are provided and a new methodic approach was introduced to describe the time-dependent behavior of the keyhole and its interaction with the melt pool during laser beam deep welding of copper (Cu-ETP/CW004A).