Weld Formation and Backside Humping Suppression Mechanism in Laser-Arc Hybrid Welding of FB780 Ferrite-Bainite Dual-Phase Steel

ZHANG Hailong; FANG Naiwen; ZHAO Zisen; XIN Guosong; WANG Xinhong; NIU Dongshanyu; CHANG Zhaoxiang; ZOU Yong

doi:10.7512/j.issn.1001-2303.2026.08.07

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Weld Formation and Backside Humping Suppression Mechanism in Laser-Arc Hybrid Welding of FB780 Ferrite-Bainite Dual-Phase Steel
Vol. 56, Issue 8, Pages: 68-79(2026)
Received：01 July 2026，

Revised：2026-08-03，

Published：20 August 2026
DOI： 10.7512/j.issn.1001-2303.2026.08.07
稿件说明：

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张海龙，方乃文，赵梓森，等.FB780双相钢激光-电弧复合焊焊缝成形与背部驼峰抑制机理研究［J］.电焊机，2026，56（8）：68-79. DOI： 10.7512/j.issn.1001-2303.2026.08.07.

ZHANG Hailong, FANG Naiwen, ZHAO Zisen, et al.Weld Formation and Backside Humping Suppression Mechanism in Laser-Arc Hybrid Welding of FB780 Ferrite-Bainite Dual-Phase Steel[J].Electric Welding Machine, 2026, 56(8): 68-79. DOI： 10.7512/j.issn.1001-2303.2026.08.07.

摘要

针对4 mm厚FB780铁素体-贝氏体双相钢激光-电弧复合焊过程中易出现背部驼峰、塌陷和气孔等成形失稳问题，采用光纤激光-电弧复合焊方法，研究热源引导方式、激光功率、焊接电流和焊接速度对焊缝成形的影响，并结合高速摄像分析电弧形态、熔滴过渡及背面成形过程。结果表明：与激光引导相比，电弧引导可通过预热母材、提高激光吸收率和稳定电弧-匙孔耦合获得更连续的正反面成形。在电弧引导、焊接电流120 A、焊接速度1.8 m/min条件下，激光功率由4.0 kW增至5.0 kW时，匙孔由临界贯通转变为稳定贯通，背部驼峰消失；继续增至5.5~6.0 kW时，根部下坠和塌陷加剧。焊接电流主要影响熔敷金属供给和熔池铺展，120 A时熔滴过渡和焊缝成形较稳定；焊接速度1.8 m/min时，单位长度热输入、匙孔稳定和熔池凝固节奏达到较好匹配。背部驼峰的形成与匙孔在部分熔透和完全熔透之间周期性切换有关，其本质是根部液桥受力平衡被破坏。与实心焊丝相比，药芯焊丝在成形评价范围内表现出更宽的工艺窗口和更好的背面成形稳定性。研究结果揭示了稳定全熔透与背部驼峰抑制之间的内在关联，为FB780高强钢复合焊接工艺窗口设计提供了实验依据。

Abstract

Formation instabilities

including backside humping

collapse and porosity

often occur during laser-arc hybrid welding of 4 mm thick FB780 ferrite-bainite dual-phase steel. In this study

a fiber laser-arc hybrid welding process was used to investigate the effects of heat-source leading mode

laser power

welding current and welding speed on weld formation

with high-speed imaging used to analyze arc morphology

droplet transfer and backside formation. The results show that the arc-leading mode produces more stable front and backside weld formation than the laser-leading mode by preheating the base metal

improving laser absorption and stabilizing arc-keyhole coupling. Under arc-leading conditions

a laser power of 5.0 kW

welding current of 120 A and welding speed of 1.8 m/min provide the best balance among heat input

keyhole stability and solidification. Increasing laser power from 4.0 kW to 5.0 kW eliminates backside humping by changing the keyhole from critical to stable penetration

whereas excessive power causes root sagging and collapse. Backside humping is mainly caused by periodic switching between partial and full penetration

which breaks the force balance of the root liquid bridge. Compared with solid wire

flux-cored wire shows a wider process window and better backside formation stability. The findings reveal the intrinsic link between sustained keyhole penetration and humping suppression

offering a practical basis for process window design in hybrid welding of FB780 high-strength steel.

关键词

Keywords

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