Finite Element Modeling of Ring and Gaussian Dual Laser Heat Sources for Aluminum Butt Welding

Abstract

Aluminum alloys have been used extensively for automotive industries for the structural applications with their high specific strength and corrosion resistance. In order to use aluminum alloys for automotive components, laser welding has been used due to the advantage of being capable to weld thick products due to its deep penetration depth. In this regard, a dual laser heat source combining an outer ring laser beam with a centrally focused Gaussian laser beam was proposed to compensate for insufficient melting caused by laser reflection of aluminum alloy. The purpose of this study is to develop a simulation model that can consider heat input from the dual laser beams individually, for analyzing melting and heat distribution behavior during the laser welding. Two different heat source models were proposed. One model used 3D Gaussian distribution of heat input for the centrally focused laser while the other model utilized Gaussian cylinder heat input. The proposed heat input models were implemented by finite element analyses, and the results were compared with aluminum butt welding experiments. It was shown that Gaussian cylinder heat input for the centrally focused laser beam reproduced much better the experimentally observed melting behavior in comparison to the 3D Gaussian distribution.