Observation of spatter formation mechanisms in high-power fiber laser welding of thick plate

•The gauffers and shelf move down into the keyhole depth with direct observation.•Raise of the constricted areas leads to melt accumulation around a narrow keyhole inlet with spatter ejection by vapor plume.•Some spatters are accelerated through the directed vapor plume outside the keyhole.•The downward flow, vapor burst with an open keyhole and gravity drive the melt off.•The spatters are generated by the viscous friction drag through the keyhole exit. This paper aims to present the dynamic behaviors of spatter formation, and to clarify the spatter formation mechanisms in the high-power fiber laser welding of a thick plate at low welding speeds. We used a modified “sandwich” specimen to directly observe the geometry of the longitudinal keyhole wall. The dynamic behaviors of the keyhole, vapor plume, and melt pool with the formation of spatters were observed using high-speed imaging. The mechanisms of the formation of the spatter ejected from the top and bottom surfaces were analyzed. The recoil momentum associated with the energized vapor plume jet acts on the tips of the gauffers on the front keyhole wall and micro-droplets inside the keyhole, thereby resulting in the formation of high-speed micro-spatter. At partial penetration, the spatter ejected from the keyhole inlet is influenced mainly by the upward melt flow above the keyhole, melt displacement around the keyhole, and the strong shear stream of the directed vapor plume force. Moreover, some spatter droplets are accelerated through the vapor plume outside the keyhole. At full penetration of the melt, spatters are generated when the downward momentum of the melt due to downward flow and gravity, or vapor burst with an open keyhole, exceeds the surface tension forces. At full penetration of the keyhole, the crucial driving force for spatter generation is the viscous friction drag associated with high-speed motion of the energized vapor plume through the open keyhole. The welding process evolves into almost a cutting process at a lower welding speed.