Heat balance and flow conditions for electron beam and laser welding

The conditions of energy and material flow during beam welding are investigated theoretically to determine the factors which govern the shape of the vapor cavity and of the molten zone. Flow conditions in the horizontal plane determine the dimensions of the weld. Material is moved around the advancing vapor cavity mainly by liquid flow, but there is some vapor flow across the cavity, providing the pressure which drives the liquid. The pressure inside the vapor cavity and its variation with depth is governed by surface tension, by the hydrostatic pressure in the liquid, and by the viscous forces acting on the vapor stream. These factors govern the radius of the cavity as a function of depth. The penetration is limited by the beam power or by the absorption of the beam. For the laser beam, absorption is decreased in the hot center, and beam penetration increases with power, but is insensitive to collimation. For electrons, absorption occurs mainly near the walls of the cavity, and the beam penetration depends on collimation and power. The balance between beam power and power dissipated by conduction, melting, and vaporization is discussed, and a self-consistent description is given of cavity formation and beam penetration.