Abstract
High-energy density beam processes for welding, including laser beam welding and electron beam welding, are essential processes in many industries and provide unique characteristics that are not available with other processes used for welding. More recently, these high-energy density beams have been used to great advantage for additive manufacturing. This review of the literature serves to provide an overview of the evolution of the laser and electron beam processes including the fundamental nature of the beam itself and how such a high-energy density beam has been applied for welding. The unique nature of each process regarding weld bead formation and penetration, and metallurgical considerations are covered in detail. In addition, the evolution of monitoring systems for both characterization and control of these beam processes is reviewed. Over 500 references have been cited in this comprehensive review that will allow the reader to both understand the current state-of-the-art and explore in more detail the fundamental concepts and practical applications of these processes.
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Abbreviations
- AE:
-
acoustic emission
- AM:
-
additive manufacturing
- BPP:
-
beam parameter product
- CAD:
-
computer-aided design
- CCD:
-
charge-coupled device
- CMOS:
-
complementary metal oxide semiconductors
- CNC:
-
computer numerical control
- CW:
-
continuous wave
- DED:
-
direct energy deposition
- DSS:
-
duplex stainless steel
- EBW:
-
electron beam welding
- EMFC:
-
enhanced modified Faraday cup
- FWHM:
-
full width at half maximum (beam size measurement)
- FZ:
-
fusion zone
- HAZ:
-
heat-affected zone
- HED:
-
high-energy density
- HLAW:
-
hybrid laser-arc welding
- ICI:
-
inline coherent imaging
- LASER:
-
light amplification by stimulated emission of radiation
- LBW:
-
laser beam welding
- LED:
-
light-emitting diode
- LENS™:
-
Laser-engineered net sha**
- LPBF:
-
laser powder bed fusion
- MASER:
-
microwave amplification by stimulated emission of radiation
- NDE:
-
nondestructive evaluation
- Nd:YAG:
-
neodymium doped yttrium aluminum garnet
- OCT:
-
optical coherence tomography
- PBF:
-
powder bed fusion
- P-LBW:
-
pulsed laser beam welding
- RPPM:
-
radiation pressure power meter
- TEM:
-
transverse electromagnetic modes
- YAG:
-
yttrium aluminum garnet
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Acknowledgements
This review was supported through the National Science Foundation (NSF) sponsored Industry/University Cooperative Research Center (I/UCRC): Manufacturing and Materials Joining Innovation Center (MA2JIC). The authors would like to thank Los Alamos National Laboratory (LANL) for providing financial support and, in particular, Dr. Matt Johnson and Dr. David Tung who have served as mentors for this project. Also, the authors would like to thank Dr. Pat Hochanadel and Dr. Tung from LANL, and Mr. Doug Kautz from Leidos Inc. for reviewing the manuscript and providing valuable input.
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Patterson, T., Hochanadel, J., Sutton, S. et al. A review of high energy density beam processes for welding and additive manufacturing applications. Weld World 65, 1235–1306 (2021). https://doi.org/10.1007/s40194-021-01116-0
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DOI: https://doi.org/10.1007/s40194-021-01116-0