In this paper, a novel laser droplet formation process (LDFP) from a metal wire is investigated. The process consists of the formation of a molten pendant droplet and its detachment, which are both unstable and influenced by numerous process parameters. The goal of the investigation is to specify the main process parameters and the values that provide for stable and repeatable process. Based on theoretical and experimental consideration of LDFP, a methodology for estimation of process control parameters is proposed. Estimation of the parameters is demonstrated on examples of deposited droplets of nickel and tin-alloy wires. Experimental results on tin-alloy wire indicate that the problem of splashes on the substrate is still present, while those on nickel reveal an acceptable formation of droplets.
Issue Section:
Technical Papers
1.
Liu
, H.
, 2000, Science and Engineering of Droplets
, Noyes
, New York.2.
Sohn
, H.
, and Yang
, D. Y.
, 2004, “Drop-on-Demand Deposition of Superheated Metal Droplets for Selective Infiltration Manufacturing
,” Mater. Sci. Eng., A
0921-5093, 392
(1–2
), pp. 415
–421
.3.
Pasandideh-Fard
, M.
, Bhola
, R.
, Chandra
, S.
, and Mostaghimi
, J.
, 1998, “Deposition of Tin Droplets on a Steel Plate: Simulations and Experiments
,” Int. J. Heat Mass Transfer
0017-9310, 41
, pp. 2929
–2945
.4.
Waldvogel
, J. M.
, and Poulikakos
, D.
, 1997, “Solidification Phenomena in Picoliter Size Solder Droplet Deposition on a Composite Substrate
,” Int. J. Heat Mass Transfer
0017-9310, 40
(2
), pp. 295
–309
.5.
Dreizin
, E. L.
, 1997, “Droplet Welding: A New Technique for Welding Electrical Contacts
,” Weld. J.
, 76
, pp. 67
–73
.6.
Appelman
, W. W.
, 1995, “Miniaturization of Droplet Deposition
,” Technical report No. CTB591-95-4070, Philips Centre for Manufacturing Technology, Eindhoven.7.
Buelens
, J. J. C.
, 1997, “Metal Droplet Deposition: Review of Innovative Joining Technique
,” Sci. Technol. Weld. Joining
1362-1718, 6
(2
), pp. 239
–243
.8.
Jahrsdörfer
, B.
, Eßer
, G.
, Geiger
, M.
, and Govekar
, E.
, 2003, “Laser Droplet Weld—An Innovative Joining Technology Opens New Application Possibilities
,” Proc. SPIE
0277-786X, 4977
, pp. 518
–529
.9.
Hoving
, W.
, and Jahrsdörfer
, B.
, 2001, “Laser Droplet Weld—Ein Innovatives Fügeverfahren
,” Laser in der Elektronikproduktion und Feinwerktechnik, LEF
2001, Bamberg, Germany.10.
Jahrsdörfer
, B.
, Schmidt
, M.
, and Geiger
, M.
, 2004, “Laser Droplet Welding and its Potential for Joining Dissimilar Materials
,” Laser Assisted Net Shape Engineering 4, Proceedings of LANE 2004
.11.
Govekar
, E.
, Jahrsdoerfer
, B.
, Klemenčič
, J.
, Mužič
, P.
, and Grabec
, I.
, 2001, “Characterization of Laser Droplet Formation Process by IR Camera Images and AE Signals
,” Dyn. Days 2001
, Dresden.12.
Govekar
, E.
, Klemenčič
, J.
, Kokalj
, T.
, Jahrsdoerfer
, B.
, Mužič
, P.
, and Grabec
, I.
, 2004, “Characterization of Laser Droplet Formation Process by Acoustic Emission
,” Ultrasonics
0041-624X, 42
, pp. 99
–103
.13.
Lancaster
, J. F.
, 1984, The Physics of Welding
, Pergamon
, Oxford, UK.14.
Crank
, J.
, 1975, The Mathematics of Diffusion
, Oxford University Press
, Oxford, UK.15.
Bäuerle
, D.
, 2000, Laser Processing and Chemistry
, Springer
, Berlin.16.
Klemenčič
, J.
, 2003, “Investigation of Laser Droplet Formation from the Wire of Small Diameter
,” University of Ljubljana
, Slovenia.17.
Iida
, T.
, and Guthrie
, R. I. L.
, 1988, The Physical Properties of Liquid Metals
, Oxford University Press
, Oxford, UK.18.
Von Allmen
, M.
, and Blatter
, A.
, 1995, Laser-Beam Interactions With Materials
, Springer
, Berlin.19.
Kroos
, J.
, Gratzke
, U.
, Vicanek
, M.
, and Simon
, G.
, 1992, “Dynamic Behavior of the Keyhole in Laser Welding
,” J. Phys. D
0022-3727, 26
, pp. 481
–486
.20.
Trappe
, J.
, Kroos
, J.
, Tix
, C.
, and Simon
, G.
, 1994, “On the Shape and Location of the Keyhole in Penetration Laser Welding
,” J. Phys. D
0022-3727, 27
, pp. 2152
–2154
.21.
Duley
, W. W.
, 1998, Laser Welding
, Wiley
, New York.22.
Ready
, J. F.
, 1997, Industrial Applications of Lasers
, Academic
, New York.23.
Bertolotti
, M.
, 1983, Physical Processes in Laser-Materials Interactions
, Plenum
, New York.24.
Gould
, R. F.
, 1964, Contact Angle, Wettability and Adhesion
, American Chemical Society
, Washington, DC.Copyright © 2006
by American Society of Mechanical Engineers
You do not currently have access to this content.
