Abstract
The growing application of laser welding in the industry motivates the development of computational models to help improve and understand the details of the laser welding process. Classical molecular dynamic (MD) or finite element (FE) methods are insufficient to model the process due to several limitations. The coupling of both methods provides a unique approach for modeling the laser welding process. A laser welding model that accounts for free-electron conduction and three-dimensional laser beam growth was developed on the basis of this coupling. The model was tested on a Cu sample, and the results showed that the amount of energy required to weld the interface was much lower than the energy used in previous studies of MD laser processes. The temperatures in the weld pool and the heat-affected zones were similar to those in previous FE studies. The crystal structure near the weld pool matched the observations of the previous MD studies. Moreover, the scanning speeds associated with this model were relatively higher than those of previous MD models due to the effects of fast electron conduction.
Highlights
Laser welding has growing applications in many industries because it offers an excellent potential for new product design
Rapid scanning speeds result in a narrow weld-affected zone, while slow scitation.org/journal/adv scanning speeds enlarges the weld-affected zone
Considering the free-electron conduction effects, which are high in most metals, low scanning speeds accumulate heat in the material and create massive weld-affected zones
Summary
Laser welding has growing applications in many industries because it offers an excellent potential for new product design. It has various advantages such as lower thermal stresses and narrower heat-affected zones (HAZs) in the workpiece than other conventional welding processes, such as arc welding and friction stir welding. The keyhole mode involves a high-intensity laser beam that strikes the metal’s surface and immediately vaporizes the metal, forming a “keyhole” containing ionized vapor.. The material melts due to the laser beam energy, but it does not vaporize. High-intensity laser beams weld under the keyhole mode, while the conduction mode requires relatively low-intensity laser beams to maintain the metal’s temperature below the vaporization point
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