Analysis of the Laser Droplet Formation Process

Abstract

In this paper, a novel laser droplet formation process (LDFP) from a metal wire is investigated. The process consists of the formation of a molten pendant droplet and its detachment, which are both unstable and influenced by numerous process parameters. The goal of the investigation is to specify the main process parameters and the values that provide for stable and repeatable process. Based on theoretical and experimental consideration of LDFP, a methodology for estimation of process control parameters is proposed. Estimation of the parameters is demonstrated on examples of deposited droplets of nickel and tin-alloy wires. Experimental results on tin-alloy wire indicate that the problem of splashes on the substrate is still present, while those on nickel reveal an acceptable formation of droplets.