1. Porosity
Causes:
Excessive welding speed: A fast speed shortens molten pool duration, trapping gas bubbles.
Surface contaminants: Oil, moisture, or rust on stainless steel decompose into gas during welding, forming pores.
Solutions:
✔ Reduce welding speed to allow gas escape.
✔ Clean surfaces thoroughly (use acetone or alcohol).
2. Cracks
Causes:
Welding stress: Rapid heating/cooling generates stress exceeding the material’s yield strength.
Poor material composition: High carbon content or unbalanced alloys reduce crack resistance.
Overly fast cooling: Forms brittle martensite, increasing crack risk.
Solutions:
✔ Pre-heat materials to slow cooling rates.
✔ Optimize alloy composition (e.g., control carbon content).
3. Sparks & Spatter
Causes:
Excessive laser energy: Overmelting causes violent metal vaporization.
Incorrect focus position: Uneven energy distribution destabilizes the molten pool.
Slow welding speed: Overheating increases metal fluidity, triggering sparks.
Solutions:
✔ Calibrate laser power to match material thickness.
✔ Adjust focus position for even energy density.
✔ Increase welding speed moderately.
