Application of Handheld Laser Welding in Locomotive Side Wall Skin Welding

ZHONG Junlin; LI Qiang; ZHOU Tianxing; YANG Shaolong; WEN Mingming; DENG Min

doi:10.7512/j.issn.1001-2303.2026.06.15

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Application of Handheld Laser Welding in Locomotive Side Wall Skin Welding
Vol. 56, Issue 6, Pages: 119-128(2026)
Received：10 April 2026，

Revised：2026-06-03，

Published：20 June 2026
DOI： 10.7512/j.issn.1001-2303.2026.06.15
稿件说明：

移动端阅览

钟俊林，李强，周天星，等.手持式激光焊接在机车侧墙蒙皮焊接中的应用［J］.电焊机，2026，56（6）：119-128. DOI： 10.7512/j.issn.1001-2303.2026.06.15.

ZHONG Junlin, LI Qiang, ZHOU Tianxing, et al.Application of Handheld Laser Welding in Locomotive Side Wall Skin Welding[J].Electric Welding Machine, 2026, 56(6): 119-128. DOI： 10.7512/j.issn.1001-2303.2026.06.15.

摘要

针对手持式激光焊接Q345NQR2耐候钢气孔敏感性强、角焊缝根部熔合困难的问题，以功率补偿为关键工艺变量，研究其对焊接头成形与气孔的影响规律，确定各接头最优工艺窗口，并通过工艺评定与工程应用验证其可行性。设计5类接头焊接工艺试验，研究功率补偿（0~90%）对接头宏观形貌、根部熔深及气孔的影响；依据ISO 15614-11：2022进行工艺评定；研制工装实现1 850 mm长直对接焊缝机械手自动化焊接；按EN 15085-4完成焊工培训与考核。结果表明：全熔透对接焊缝排气充分、气孔少，满足ISO 13919-1：2021 B级，而带垫板焊缝因排气受限易产生条虫状气孔；功率补偿调控激光能量分布，对接焊缝功率补偿为0时呈Ⅰ型成形良好，角焊缝功率补偿≥60%时焊缝由倒M型转为U型、根部完全熔合；卷边焊缝因送丝定位困难不适用。经工艺评定，对接焊接头抗拉强度506~517 MPa，均断于母材外侧；该工艺已应用于4台出口机车侧墙焊接，焊后平面度优于富氩气保焊，车体静强度试验后焊缝无缺陷，表明手持激光焊接工艺可满足轨道车辆薄壁结构的工程要求。

Abstract

To address the strong porosity sensitivity and difficulty in root fusion of fillet welds during handheld laser welding of Q345NQR2 weathering steel

power compensation was taken as the key process variable to investigate its effects on weld formation and porosity

determine the optimal process windows for various joint types

and verify the feasibility through procedure qualification and engineering application. Welding tests were designed for five joint types to systematically study the effects of power compensation (0-90%) on weld macro-morphology

root penetration

and porosity; procedure qualification was conducted per ISO 15614-11:2022; tooling was developed to enable robotic welding of 1 850 mm long butt seams; welder training and qualification were completed per EN 15085-4.

Results

show that full-penetration butt welds allow sufficient gas escape with few pores

meeting ISO 13919-1:2021 level B

while backed butt welds are prone to wormhole porosity due to restricted gas escape. Power compensation regulates laser energy distribution: butt welds form I-type profile at power compensation of 0

while fillet welds transform from inverted-M to U-type with complete root fusion at power compensation ≥60%. Flanged joints are unsuitable due to wire feeding and positioning difficulties. Qualified butt weld tensile strength reaches 506-517 MPa with fractures outside the weld. The process has been applied to four export locomotive side walls

achieving better flatness than GMAW and no weld defects after carbody static strength testing

demonstrating that handheld laser welding can meet the engineering requirements for thin-walled structures in rail vehicles.

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