Journal of Welding and Joining

The Korean Welding and Joining Society (대한용접접합학회)
권호 표지
DOI QR코드

DOI QR Code

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)
  • Received : 2017.01.18
  • Accepted : 2017.02.15
  • Published : 2017.04.30
Download PDF
⟨ Previous Next ⟩

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

References

  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 https://doi.org/10.1088/0022-3727/39/21/030
  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 https://doi.org/10.1016/j.optlaseng.2013.01.008
  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 https://doi.org/10.1179/1362171813Y.0000000180
  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 https://doi.org/10.2351/1.1324717
  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. https://doi.org/10.1016/j.jmatprotec.2011.04.002
  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 https://doi.org/10.1088/0022-3727/38/12/005
  7. Abt, F., et al., Camera based closed loop control for partial penetration welding of overlap joints. physics procedia, 12 (2011), 730-738 https://doi.org/10.1016/j.phpro.2011.03.091
  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 https://doi.org/10.1016/j.phpro.2011.03.090
  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 https://doi.org/10.1007/s00340-012-5104-8
  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 https://doi.org/10.1016/j.optlastec.2013.03.001
  11. S., O. and F.R. P., Level set method, an overview and some recent results. Journal of computation physics, 169 (2001), 463-502 https://doi.org/10.1006/jcph.2000.6636
  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 https://doi.org/10.1016/0021-9991(81)90145-5
  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 https://doi.org/10.1007/s11661-002-0190-6
  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 https://doi.org/10.1088/0022-3727/35/13/320
  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 https://doi.org/10.1088/0022-3727/39/24/036
  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 https://doi.org/10.1063/1.2777132
  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 https://doi.org/10.1088/0022-3727/41/5/055503
  18. 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 https://doi.org/10.1088/0022-3727/42/17/175502
  19. 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 https://doi.org/10.1088/0022-3727/44/48/485302
  20. 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 https://doi.org/10.1088/0022-3727/46/5/055501
  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 https://doi.org/10.1088/0022-3727/35/10/313
  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 https://doi.org/10.1016/S0963-8695(00)00017-7
  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 https://doi.org/10.1007/s002310050373
  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 https://doi.org/10.1007/s11740-008-0148-7
  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 https://doi.org/10.1006/jcph.1996.0072
  27. 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 https://doi.org/10.1006/jcph.2000.6537
  28. 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 https://doi.org/10.1063/1.3474655
  29. Knight, C.J., Theoretical modeling of rapid surface vaporization with back pressure. AIAA journal, 17(5) (1979), 519-523 https://doi.org/10.2514/3.61164
  30. 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 https://doi.org/10.1088/0022-3727/34/3/320