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Laser Welding Machine: Causes and Prevention of Weld Porosity
szhaiwei
2025-09-03
Porosity is a common defect in laser welding that can weaken joints and affect product reliability. Even with a high-quality laser welding machine, small gas pockets may appear in the weld bead. Understanding the root causes helps operators improve process stability and part quality.
Material Contamination
One of the main reasons for pores is surface contamination. Oil, moisture, oxide layers, or residues on the metal surface vaporize during welding and get trapped in the solidifying melt pool. This is especially common in aluminum and copper alloys. Cleaning parts before welding—using solvents or mechanical methods—can significantly reduce this risk.
Shielding Gas Issues
Inadequate shielding gas coverage allows air to enter the weld zone, leading to nitrogen or oxygen absorption. Insufficient flow, incorrect nozzle angle, or blockages can all compromise protection. Using the right gas type (argon or argon-helium mix), proper flow rate (15–20 L/min), and well-positioned nozzles helps prevent pores.
Welding Parameters and Melt Pool Dynamics
Too high a laser power or too fast a travel speed can create an unstable keyhole. When the keyhole collapses irregularly, it may trap gas inside. Beam oscillation (wobble welding) improves gas escape by controlling melt pool flow and reducing deep, narrow cavities. Adjusting focus position and using multi-pulse waveforms also help stabilize the process.
Joint Fit-Up and Gap Control
Gaps between parts can cause shielding gas to escape or allow air entrapment. In fillet or lap joints, even small misalignments increase the risk of pores. Using precision fixtures and adaptive seam tracking on the laser welding machine ensures consistent fit-up.
Real-Time Monitoring for Prevention
Advanced systems offer in-process monitoring to detect conditions that lead to porosity. While direct pore detection is still limited, monitoring melt pool behavior can signal instability early.
For users, selecting a laser welding machine with parameter flexibility, gas control, and process feedback supports consistent results. Addressing contamination, gas shielding, and joint quality remains key to minimizing pores in production.
REPORT