Direction-independent laser-GMA hybrid welding with coaxial wire feed and annular beam

Conventional laser gas metal arc hybrid welding (LB-GMA hybrid welding) is used as an efficient joining process in several high-tech steel processing production facilities. However, the use of the LB-GMA hybrid welding is often limited to the joining of linear weld seams as the welding process has a preferred welding direction due to lateral positioning of the laser beam and welding wire electrode. Reorienting the welding direction, therefore, often results in weld defects since changing the welding direction also requires a geometric manipulation of the GMA torch in relation to the laser beam optics. This means a considerable additional effort that is necessary if this efficient welding process is to be used for geometrically complex weld seam contours. Furthermore, the conventional LB-GMA hybrid welding process has a high adjustment complexity. Within this work, a direction-independent laser GMA hybrid welding head with an annular beam and coaxial wire feed is used. The annular laser beam with homogenous intensity profile is formed by a special processing head, split and reassembled around the coaxial wire. Due to the coaxial arrangement of the wire electrode to the annular beam, the hybrid process is in theory direction independent. As a result, there should not be any irregularities in the weld seam, when the welding direction is changed. The annular beam considerably reduces the complexity of adjustment and improves reproducibility. The focus of this work is to qualify the process for joining geometrically complex weld contours and to investigate possible advantages of the directional independence of the coaxial LB-GMA hybrid welding process. For this purpose, fillet welds in lap joint configuration with a sheet thickness of 2 mm each at different weld contours (different direction changes, corners, radii) are discussed. By performing a DoE-based sensitivity analysis, influencing factors on the quality of the generated weld are analysed.