Mechanisms of Spatter Formation and Suppression in Aluminum Alloy via Hybrid Fiber–Semiconductor Laser System
, Di Wu 1,2,*, Xiaoting Li 3,*, Fangyi Yang 1,2, Peilei Zhang 1,2, Haichuan Shi 1,2 and Zhishui Yu 1,2
Round 1
Reviewer 1 Report
Comments and Suggestions for AuthorsThe article examines laser welding of aluminum alloys, which has become the predominant joining method due to its high energy density, high processing speed and flexibility in operation. High-speed photography and three-dimensional numerical modeling of heat and mass transfer in a melt bath are used. The spraying process for single-mode Gaussian laser beams and two-beam hybrid laser systems is analyzed. The numerical simulation of the melt bath profile coincides with the experimentally measured one. The mechanisms of splashing are associated with the instability of the boundary of the melt bath, but the details are not specified. The work has been done at a high scientific level and should certainly be published, after minor changes.
- It is necessary to clarify the nature of the boundary instability, for example, thermocapillary instability of the inner boundary of the melt bath at evaporative pressure or some other instability.
- Apparently, it is necessary to point to references [1,2], where similar problems were considered. For example, in [2], Figures 7 and 8 show the melt bath profiles obtained as a result of numerical simulation. You can see the wave nature of the border development.
- To include the issues of thermocapillary instability under the action of evaporative pressure in the directions of future research.
Wang, L.; Zhao, Y.; Li, Y.; Zhan, X. Droplet Transfer Induced Keyhole Fluctuation and Its Influence Regulation on Porosity Rate during Hybrid Laser Arc Welding of Aluminum Alloys. Metals 2021, 11, 1510. https://doi.org/10.3390/met11101510
Ke W, Bu X, Oliveira J, Xu W, Wang Z, Zeng Z (2021) Modeling and numerical study of keyhole-induced porosity formation in laser beam oscillating welding of 5a06 aluminum alloy. Opt Laser Technol 133:106540. https://doi.org/10.1016/j.optlastec.2020.106540
Author Response
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Author Response.pdf
Reviewer 2 Report
Comments and Suggestions for AuthorsThis study investigates spatter formation and suppression in aluminum alloy welding using a hybrid fiber-semiconductor laser system, integrating high-speed photography and numerical simulations. The suggested method is innovative and would be expected to provide very useful information to related researchers.
- In introduction section, it clearly sets context but could be improved by emphasizing why systematic investigation into spatter suppression is particularly critical for aluminum alloys.
- In 2.1 section, briefly justify the choice of the specific alloy (3003 Al-Mn alloy) and the selected welding parameters, clarifying why these parameters were chosen or why they are particularly relevant.
- In Fig. 1(b), make sure to explain whether these data are measured or referenced.
- Eq. (4) is not clear. Author used k!, but it not clearly explained the meaning .
- Eq. (4) looks like 2D model for surface heating instead of 3D model. However, Eq.17) explains 3D Gaussian heat source.
- There are two Eq. (17).
- Eq.(8)-Eq.(18), they are simply explain the concept of VOF. It seems redundant.
- The simulation should be validated. If authors have some prior results, please cite them for the validation.
- 3.3.1 ~ 3.3.2 are well explained for the physics of key hole formation and welding. However, results in Fig. 10 and Fig. 11 are not correlated.
- Some quantitative data are required to make conclusion. In figure 11, two lasers are effective, but those two figures are not enough to support this paper.
Author Response
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