Numerical study on weld pool behaviors and keyhole dynamics in magnetic-field-assisted laser-arc hybrid welding of aluminum alloy

Abstract

External magnetic field has been employed to improve appearance and suppress defects in the single laser or arc welding, and its physical mechanism in magnetic-field-assisted single laser or arc welding has been clearly clarified. However, few studies on the physical processes in magnetic-field-assisted laser-arc hybrid welding (MFA-LAHW) are conducted and its influencing mechanism is unclear. In this research, a comprehensive three-dimension numerical model is established to investigate the keyhole dynamics and weld pool behaviors in MFA-LAHW under the effect of different magnetic flux density. The results suggest that the interaction between a lower magnetic flux density (≤30 mT) and welding current is induced due to the existence of arc. Compared to the magnetic-field-assisted laser beam welding (MFA-LBW), this interaction induces a stronger Lorentz force up to the order of magnitude of 105 N/m3. The weld pool width is reduced while its length and height are increased because the Lorentz force facilitates the backward flow of thermal fluid, increasing the heat transfer from the keyhole and droplet to the rear weld pool edge. Moreover, the steady magnetic field improves the keyhole stability. The deform on keyhole rear wall brought by the droplet and vortex is suppressed, and keyhole size is widened under steady magnetic field, which reduced keyhole collapse. Furthermore, the comparative analysis with the case in MFA-LBW is carried out and the MFA-LAHW is verified to be more valuable for medium-thickness aluminum alloy. This work provides the underlying physics understanding of MFA-LAHW, which will broaden the application value of LAHW.