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Optimizing Laser Power and Pulse Frequency Matching for Rocker Arm Laser Spot Welding of 2mm Stainless Steel
Views: 0 Author: Site Editor Publish Time: 2025-08-28 Origin: Site
When performing rocker arm laser spot welding on 2mm-thick stainless steel, the core goal of optimizing the matching between laser power and pulse frequency is to achieve sufficient penetration depth, minimal heat-affected zone (HAZ), and uniform weld spot formation. The key lies in balancing the single-pulse energy and heat accumulation effect, which can be specifically analyzed from the following dimensions:
1.Clarify the Basic Matching Logic of Power and Frequency
Laser power, as the core determinant of single-pulse energy, must meet the penetration requirements of 2mm stainless steel (typically requiring an effective penetration depth of 0.8–1.2mm). Pulse frequency, on the other hand, determines the weld spot density per unit time and the continuity of heat input.
If the power is insufficient (resulting in inadequate single-pulse energy), even increasing the frequency will lead to "cold welding" of individual weld spots due to insufficient penetration.
If the power is excessively high while the frequency is also too high, severe heat accumulation between adjacent weld spots will occur, causing coarse grains in the stainless steel, oxidation (discoloration) at the weld spot edges, and even local burn-through.
2.Parameter Adjustment Directions for Typical Problems
When "Weld Spot Lack of Fusion + Edge Cold Welding" Occurs
The core issue is insufficient single-pulse energy. Priority should be given to increasing the laser power (e.g., from 800W to 1000–1200W, adjusted according to the rated power of the equipment) to ensure that a single pulse can break through the oxide film and form an effective molten pool. At the same time, reduce the pulse frequency appropriately (e.g., from 50Hz to 30–40Hz) to reduce heat input overlap and avoid reduced bonding strength in the non-fused area caused by continuous cold impact.
When "Weld Spot Burn-Through + Excessively Large HAZ" Occurs
This is mainly due to excessive single-pulse energy and severe heat accumulation. First, lower the laser power (e.g., from 1500W to 1200W) to reduce the volume of the single molten pool. Meanwhile, increase the pulse frequency moderately (e.g., from 30Hz to 40–50Hz). By shortening the interval time between adjacent weld spots and matching the pulse frequency with the rocker arm movement speed (e.g., frequency = rocker arm movement speed / weld spot spacing), heat input can be dispersed and local overheating suppressed.
When "Uneven Weld Spot Formation (Sporadically Large or Small)" Occurs
This is mostly caused by mismatched dynamic responses between power and frequency (e.g., frequency not adjusted synchronously when power fluctuates). It is necessary to fix a power baseline (e.g., 1000W) and adjust the coordination between frequency and rocker arm movement (e.g., adjusting the frequency proportionally to the rocker arm movement speed) to ensure uniform energy input per unit length.
3.Summary of Optimization Principles
For 2mm stainless steel, it is recommended to first determine the effective single-pulse energy based on the "power priority" principle (to ensure penetration depth), then control heat accumulation using the "frequency adaptation" principle (to avoid thermal deformation). Generally, the recommended parameter range is 800–1200W for laser power and 30–50Hz for pulse frequency (adjustable according to the equipment’s spot diameter; smaller spot diameters allow for appropriate power reduction). Finally, verify the matching effect by observing the cross-section of the weld spot (whether the penetration depth is uniform) and the surface (whether there is oxidation or depression) through test welding.
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