Effects of groove clearance size on gap bridging capacity in PWLBW of Ti6Al4V alloy sheet assembled in butt joint configuration: Numerical simulation and experimental assessment

Abstract

In laser tailor-welding of metal sheets, it is difficult to keep the assembly clearance fixed due to plate specification deviation, tooling error, and thermal deformation. In this paper, the influence of clearance size on gap bridging capacity and in turn the seam appearance quality was investigated for thin Ti6Al4V alloy plates, configured by an improved pulse wave laser beam welding (PWLBW) scheme. The welding experiment and the numerical simulation were performed at 1.2 mm-thick workpieces assembled in a butt joint with a reserved clearance. With the clearance size enlarged from 0.2 mm to 0.4 mm, the gap bridging type changes from bilateral to unilateral, which results in the failure of the keyhole to rebound during the pulse interval, and causes an obvious reduction in metal bridge area at the cross-section. As the clearance increases further, a through-cavity geometry is generated between the weld spots and finally preserved within the solidified weld bead, indicating a poor overlapping effect. The dynamics of the weld pool, including thermal cycle, Marangoni convection, and molten metal flow rate are exquisitely sensitive to the change in clearance size. The clearance size during assembly and welding processes should be controlled below 0.4 mm to attain seam integrity, continuity, and sound tensile property.