The wire feeding principle in a fiber laser welding machine involves the controlled addition of filler material (welding wire) into the molten pool created by the laser beam. This process enhances joint strength, fills gaps, and improves weld quality, especially for thicker or dissimilar materials. Here's how it works:
Key Components Involved:
Laser Source – Generates a high-power, focused laser beam (typically fiber laser with wavelengths of 1070–1080 nm).
Wire Feeder System – Precisely feeds filler wire into the weld zone.
Welding Torch/Head – Integrates the laser beam and wire feeding nozzle.
Motion System – Controls the relative movement between the workpiece and the welding head.
Wire Feeding Principles:
Synchronized Feeding
The wire is fed at a controlled speed (synchronized with laser power and travel speed).
Proper synchronization ensures smooth melting of the wire into the molten pool without spatter or incomplete fusion.
Feeding Direction
Front Feeding (Push Feeding): Wire is fed from the front side of the laser beam (common for deep penetration welds).
Side Feeding: Wire is fed at an angle (typically 30°–60°) to avoid laser beam obstruction.
Rear Feeding: Wire is fed from behind the laser beam (improves stability for certain applications).
Wire Positioning
The wire tip must be accurately placed near the laser focus point to ensure proper melting.
Too far → Incomplete melting.
Too close → Wire may block the laser or cause instability.
Wire Melting Mechanism
The laser beam directly irradiates the wire and workpiece, melting them simultaneously.
Some systems use indirect heating (molten pool transfers heat to the wire).
Closed-Loop Control (Advanced Systems)
Sensors monitor the molten pool and adjust wire speed/laser power in real-time for consistent quality.
