Abstract
This paper presents an experimentally validated weld joint shape and dimensions predictive 3D modeling for low carbon galvanized steel in butt-joint configurations. The proposed modelling approach is based on metallurgical transformations using temperature dependent material properties and the enthalpy method. Conduction and keyhole modes welding are investigated using surface and volumetric heat sources, respectively. Transition between the heat sources is carried out according to the power density and interaction time. Simulations are carried out using 3D finite element model on commercial software. The simulation results of the weld shape and dimensions are validated using a structured experimental investigation based on Taguchi method. Experimental validation conducted on a 3 kW Nd: YAG laser source reveals that the modelling approach can provide not only a consistent and accurate prediction of the weld characteristics under variable welding parameters and conditions but also a comprehensive and quantitative analysis of process parameters effects. The results show great concordance between predicted and measured values for the weld joint shape and dimensions.
Highlights
The laser welding process has gained importance in fabrication industries due to its ability to produce precise welds with small heat affected zones [1]
The values of bead width (BDW) and depth of penetration (DOP) of the weld are measured on the thermal fields using the concept that the limit of the melted pool is the liquidus temperature
The results reveal that the predicted DOP and BDW are in good agreement with the experimental observations with small average errors of 6% and 11% for DOP and BDW respectively
Summary
The laser welding process has gained importance in fabrication industries due to its ability to produce precise welds with small heat affected zones [1]. A study has been conducted on the deformation caused by thermally induced stresses that can result in a change of the gap width between the welded parts [14] These displacements are studied through both experiments and simulations. An investigation on gap bridging of pulsed laser welding reveals an advanced finite element model with fluid motion and free surface physics [15]. The weld pool shape and dimensions are studied in continuous wave butt joint laser welding The particularity of this simulation is the addition of the gap as a parameter of the simulation, and the prediction of the underfill for a full penetration weld. Conduction mode and keyhole mode are covered in this model, using different heat sources according to the power density and interaction time. A 3 kW Nd: YAG laser for welding low carbon galvanized steel is used for the experimental investigation
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