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<p>Penetration depth is a critical indicator of joint quality in laser welding. However, conventional continuous wave and pulsed modes suffer from excessive heat input and uncontrollable melt pool dynamics, resulting in limited penetration and porosity defects. Although continuous wave power modulation has been employed to synergistically enhance penetration and suppress defects, its stepwise regulation lacks sufficient precision. This study proposes a novel pulsed laser welding process based on spatially resolved energy element control, enabling precise regulation of melt pool behavior through site-specific energy delivery. Compared with conventional constant-energy welding, the proposed approach reduced peak temperature in the far field by 22.47 °C, increased average molten depth by 82.27 μm, and decreased porosity by 2.62–40.18%. Comparative analysis of four modulation modes revealed a performance hierarchy: conventional pulsed &lt; asymmetric power dual-pulse &lt; three-power stepped pulse &lt; variable-frequency three-power stepped pulse (optimal). The 870 W/540 W/330 W triple-step energy configuration achieved the lowest porosity and substantially greater penetration depth than reference values. By distributing discrete energy elements of varying magnitudes across spatial locations at an average power of 870 W, this strategy achieves superior weld quality through localized thermal management rather than increasing global heat input.</p>

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Analysis of laser welding process and porosity suppression based on controllable adjustment of energy and distribution

  • 期刊论文

  • 发表日期：

    2026年5月4日

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  • Yazhou Jia,
  • Zipeng Yao,
  • Yunjing Chen,
  • Huixing Yan,
  • Ruchuan Zeng,
  • Qiang Ling,
  • Ning Huang

摘要

Penetration depth is a critical indicator of joint quality in laser welding. However, conventional continuous wave and pulsed modes suffer from excessive heat input and uncontrollable melt pool dynamics, resulting in limited penetration and porosity defects. Although continuous wave power modulation has been employed to synergistically enhance penetration and suppress defects, its stepwise regulation lacks sufficient precision. This study proposes a novel pulsed laser welding process based on spatially resolved energy element control, enabling precise regulation of melt pool behavior through site-specific energy delivery. Compared with conventional constant-energy welding, the proposed approach reduced peak temperature in the far field by 22.47 °C, increased average molten depth by 82.27 μm, and decreased porosity by 2.62–40.18%. Comparative analysis of four modulation modes revealed a performance hierarchy: conventional pulsed < asymmetric power dual-pulse < three-power stepped pulse < variable-frequency three-power stepped pulse (optimal). The 870 W/540 W/330 W triple-step energy configuration achieved the lowest porosity and substantially greater penetration depth than reference values. By distributing discrete energy elements of varying magnitudes across spatial locations at an average power of 870 W, this strategy achieves superior weld quality through localized thermal management rather than increasing global heat input.