Impact of laser beam shaping on weld pool and seam geometry in butt-joint welding with filler wire

Abstract

Abstract Beam shaping offers a promising solution to address various challenges in laser-based processes. This study explores the use of an adaptive beam shaping solution using a deformable mirror for high-power continuous wave lasers. Specifically, the impact of three different elliptical beam shapes on weld pool geometry, weld cross section in butt-joint welding with a filler wire is investigated. The results reveal that beam shaping significantly affects the weld pool and cross section, with elliptical beam shapes resulting in wider fusion zones in two tested cases and more uniform weld bead compared to a typical circular beam. These findings highlight the potential of beam shaping for enhancing consistency and quality in laser beam welding.