Abstract
A two-dimensional finite-element nonlinear transient heat conduction model was developed and used to simulate deep-penetration keyhole laser welds in aluminum alloys. The weld thermal profiles were calculated in an arbitrary reference plane as the laser beam approached and passed the plane. From the calculated thermal profiles, three-dimensional quasi-steady-state shapes of the weld pools were determined. The predicted weld bead shape and dimensions were in good agreement with the experimental results. The experimental laser welds in aluminum alloys contained large amounts of porosity. The model predicted large mushy zones for aluminum laser welds during solidification, which in turn increase the probability of porosity formation by increased bubble entrapment.
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