Browse > Article
http://dx.doi.org/10.5781/JWJ.2017.35.2.3

Numerical Simulation of Transport Phenomena for Laser Full Penetration Welding  

Zhao, Hongbo (Intelligent Laser Advanced Manufacturing Laboratory, University of Michigan - Shanghai Jiao Tong University Joint Institute, Shanghai Jiao Tong University)
Qi, Huan (Intelligent Laser Advanced Manufacturing Laboratory, University of Michigan - Shanghai Jiao Tong University Joint Institute, Shanghai Jiao Tong University)
Publication Information
Journal of Welding and Joining / v.35, no.2, 2017 , pp. 13-22 More about this Journal
Abstract
In laser full penetration welding process, full penetration hole(FPH) is formed as a result of force balance between the vapor pressure and the surface tension of the surrounding molten metal. In this work, a three-dimensional numerical model based on a conserved-mass level-set method is developed to simulate the transport phenomena during laser full penetration welding process, including full penetration keyhole dynamics. Ray trancing model is applied to simulate multi-reflection phenomena in the keyhole wall. The ghost fluid method and continuum method are used to deal with liquid/vapor interface and solid/liquid interface. The effects of processing parameters including laser power and scanning speed on the resultant full penetration hole diameter, laser energy distribution and energy absorption efficiency are studied. The model is validated against experimental results. The diameter of full penetration hole calculated by the simulation model agrees well with the coaxial images captured during laser welding of thin stainless steel plates. Numerical simulation results show that increase of laser power and decrease of welding speed can enlarge the full penetration hole, which decreases laser energy efficiency.
Keywords
Laser full penetration welding; Full penetration hole; FVM; Mass conserved level set;
Citations & Related Records
연도 인용수 순위
  • Reference
1 Jin, X., P. Berger, and T. Graf, Multiple reflections and Fresnel absorption in an actual 3D keyhole during deep penetration laser welding. Journal of Physics D, Applied Physics, 39(21) (2006), 4703   DOI
2 Eriksson, I., J. Powell, and A. Kaplan, Melt behavior on the keyhole front during high speed laser welding. Optics and Lasers in Engineering, 51(6) (2013), 735-740   DOI
3 You, D., X. Gao, and S. Katayama, Review of laser welding monitoring. Science and Technology of Welding and Joining, 19(3) (2014), 181-201   DOI
4 Seto, N., S. Katayama, and A. Matsunawa, High-speed simultaneous observation of plasma and keyhole behavior during high power $CO_2$ laser welding, effect of shielding gas on porosity formation. Journal of laser applications, 12(6) (2000), 245-250   DOI
5 Kawahito, Y., et al., Relationship of laser absorption to keyhole behavior in high power fiber laser welding of stainless steel and aluminum alloy. Journal of Materials Processing Technology, 211(10) (2011), 1563-1568.   DOI
6 Fabbro, R., et al., Study of keyhole behaviour for full penetration Nd-Yag CW laser welding. Journal of physics D, Applied physics, 38(12) (2005), 1881   DOI
7 Abt, F., et al., Camera based closed loop control for partial penetration welding of overlap joints. physics procedia, 12 (2011), 730-738   DOI
8 Blug, A., et al., Closed-loop control of laser power using the full penetration hole image feature in aluminum welding processes. physics procedia, 12 (2011), 720-729   DOI
9 Blug, A., et al., The full penetration hole as a stochastic process, controlling penetration depth in keyhole laserwelding processes. Applied Physics B, 108(1) (2012), 97-107   DOI
10 Zhang, Y., et al., Coaxial monitoring of the fibre laser lap welding of Zn-coated steel sheets using an auxiliary illuminant. Optics & Laser Technology, 50 (2013), 167-175   DOI
11 S., O. and F.R. P., Level set method, an overview and some recent results. Journal of computation physics, 169 (2001), 463-502   DOI
12 Hirt, C.W. and B.D. Nichols, Volume of fluid (VOF) method for the dynamics of free boundaries. Journal of computational physics, 39(1) (1981), 201-225   DOI
13 Ki, H., J. Mazumder, and P.S. Mohanty, Modeling of laser keyhole welding, Part I. Mathematical modeling, numerical methodology, role of recoil pressure, multiple reflections, and free surface evolution. Metallurgical and materials transactions A, 33(6) ((2002), 1817-1830   DOI
14 Y., L.J. and K.S. H., Mechanism of keyhole formation and stability in stationary laser welding. Journal of Physics D, Applied Physics, 35 (2002), 1570-1576   DOI
15 Zhou, J., H.-L. Tsai, and T. Lehnhoff, Investigation of transport phenomena and defect formation in pulsed laser keyhole welding of zinc-coated steels. Journal of Physics D, Applied Physics, 39(24) (2006), 5338   DOI
16 Dasgupta, A., J. Mazumder, and P. Li, Physics of zinc vaporization and plasma absorption during $CO_2$ laser welding. Journal of Applied Physics, 102(5) (2007), 053108   DOI
17 Amara, E. and R. Fabbro, Modelling of gas jet effect on the melt pool movements during deep penetration laser welding. Journal of Physics D, Applied Physics, 41(5) (2008), 055503   DOI
18 Tan, W., N.S. Bailey, and Y.C. Shin, Investigation of keyhole plume and molten pool based on a three-dimensional dynamic model with sharp interface formulation. Journal of Physics D, Applied Physics, 46(5) (2013), 055501   DOI
19 Cho, J.-H., et al., Weld pool flows during initial stages of keyhole formation in laser welding. Journal of Physics D, Applied Physics, 42(17) (2009), 175502   DOI
20 Zhao, H., et al., Modelling of keyhole dynamics and porosity formation considering the adaptive keyhole shape and three-phase coupling during deep-penetration laser welding. Journal of Physics D, Applied Physics, 44(48) (2011), 485302   DOI
21 Ye, X.-H. and X. Chen, Three-dimensional modelling of heat transfer and fluid flow in laser full-penetration welding. Journal of Physics D, Applied Physics, 35(10) (2002), 1049   DOI
22 Brüggemann, G., A. Mahrle, and T. Benziger, Comparison of experimental determined and numerical simulated temperature fields for quality assurance at laser beam welding of steels and aluminium alloyings. NDT & E International, 33(7) (2000), 453-463   DOI
23 Mahrle, A., J. Schmidt, and D. Weiss, Simulation of temperature fields in arc and beam welding. Heat and Mass transfer, 36(2) (2000), 117-126   DOI
24 Geiger, M., et al., A 3D transient model of keyhole and melt pool dynamics in laser beam welding applied to the joining of zinc coated sheets. Production Engineering, 3(2) (2009), 127-136   DOI
25 Osher, S. and R. Fedkiw, Level set methods and dynamic implicit surfaces. Springer Science & Business Media, 153 (2006)
26 Chang, Y.-C., et al., A level set formulation of Eulerian interface capturing methods for incompressible fluid flows. Journal of computational Physics, 124(2) (1996), 449-464   DOI
27 Ki, H., P. Mohanty, and J. Mazumder, Modelling of high-density laser-material interaction using fast level set method. Journal of Physics D, Applied Physics, 34(3) (2001), 364   DOI
28 Sussman, M. and E.G. Puckett, A coupled level set and volume-of-fluid method for computing 3D and axisymmetric incompressible two-phase flows. Journal of Computational Physics, 162(2) (2000), 301-337   DOI
29 Wen, S. and Y.C. Shin, Modeling of transport phenomena during the coaxial laser direct deposition process. Journal of Applied Physics, 108(4) (2010), 044908   DOI
30 Knight, C.J., Theoretical modeling of rapid surface vaporization with back pressure. AIAA journal, 17(5) (1979), 519-523   DOI