Description
In the present work a camera-based process observation system was evaluated and used for analyzing the welding of zinc-coated steel sheets in overlap configuration. Using this system, the melt and vapor flow around the interaction zone between laser and material could be monitored. Moreover, a measurement of the zinc evaporation inside the keyhole could be obtained using tracer particles. For quantifying the melt flow, the evaporation of the sheet material and the evaporation of the zinc coating image processing algorithms have been used. The resulting data was then used for the development of an analytical process model of the welding process of zinc-coated steel sheets in overlap configuration. By using this model, it could be shown that the zinc coating and the joining gap between the sheets have an influence on the pressures due to the melt and vapor flow inside the keyhole which in turn shows an effect on the keyhole geometry. These results led to the development of a new approach for the adaptive control of the joining gap during the welding process by imaging the keyhole opening length.
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