Plasma plume oscillations during welding of thin metal sheets with a CW CO2 laser

An analysis is presented of the oscillations of keyhole pressure and plasma radiation emitted during welding with a continuous wave (CW) CO2 laser. Welding was done with a CW CO2 laser, Photon Sources VFA 2500, operating at the power of 1.75 kW. The welded materials were mild and stainless steel sheets, 0.8-2 mm thick. The shielding gas was argon or helium. Oscillations of plasma radiation were registered in monochromatic or broad band radiation with the use of a photomultiplier or photodiode and pressure variations with a microphone in the frequency range of 20-2 x 10(4) Hz. It has been found that the optical signal from the plasma plume is closely connected with the acoustic signal and that the source of the acoustic signal is the pulsating movement of the plasma plume. Spectral analysis of the measured oscillations shows differences in power spectra depending on the welding conditions. Generally, two intrinsic frequency peaks in the range of 0.5-4 kHz are always present but the amplitude, frequency and width of the peaks depend on the material and welding conditions. The results show that the optical and acoustic signals emitted during the welding process can be useful for process monitoring. The behaviour of the observed oscillations is characteristic for deterministic chaos. Considerable regularization of the process was observed as an effect of modulation of the laser beam. The modulation factor (Pmax - P-min) / P-max was equal to 0.2 and the modulation frequency was 2 kHz. In this case, the intense peak corresponding to the modulation frequency was observed in the power spectrum together with smaller peaks corresponding to the harmonic frequencies.