FEM Simulation of Dissimilar Aluminum Titanium Fiber Laser Welding Using 2D and 3D Gaussian Heat Sources

Sonia D’Ostuni,Paola Leo,Giuseppe Casalino

doi:10.3390/met7080307

Sonia D’Ostuni, Paola Leo + Show 1 more

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https://doi.org/10.3390/met7080307

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Abstract

For a dissimilar laser weld, the model of the heat source is a paramount boundary condition for the prediction of the thermal phenomena, which occur during the welding cycle. In this paper, both two-dimensional (2D) and three-dimensional (3D) Gaussian heat sources were studied for the thermal analysis of the fiber laser welding of titanium and aluminum dissimilar butt joint. The models were calibrated comparing the fusion zone of the experiment with that of the numerical model. The actual temperature during the welding cycle was registered by a thermocouple and used for validation of the numerical model. When it came to calculate the fusion zone dimensions in the transversal section, the 2D heat source showed more accurate results. The 3D heat source provided better results for the simulated weld pool and cooling rate.

Highlights

Laser welding is recognized as an effective process to weld metals with a laser beam of high-power, high-energy density
Ti6Al4V/AA5754 laser laser welded weldedjoint jointafter afterchemical chemicaletching etchingisisshown shownininFigure. Both titanium and aluminum alloy melted at the joint interface and separate fusion zones were
Both titanium and aluminum alloy melted at the joint interface and separate fusion zones were observed

Summary

Introduction

Laser welding is recognized as an effective process to weld metals with a laser beam of high-power, high-energy density. The power density of a laser beam is much higher than that of arc or plasma. A deep narrow penetration weld can be effectively produced. These properties have made laser welding a suitable technology for weldments that are made from metals of different compositions and properties [1,2]. Between the different Al/Ti welding processes laser welding offers numerous advantages. High energy density, high cooling and heating rate allow for reducing the importance of mixing and diffusion phenomena, and reduce the formation of intermetallic compounds in the case of dissimilar joints. The quality depends heavily on the process parameters, which determine the magnitude of thermal stresses [5]

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