The role of asymmetric metal flow on weld formation and solidification characteristics during pulsed laser butt welding with assembly tolerance

Abstract

In comparison to other laser-assisted welding techniques, the pulsed laser welding process (PLBW) provides cost-effectiveness and ease of operation while effectively connecting butt-assembled thin plates with manufacturing tolerances (both air gap and edge misalignment). A combination of numerical simulations and experimental studies was conducted to analyze the forming mechanism and solidification behavior of the weld. In this paper, a transient three-dimensional heat-flow-metallurgical model has been established for a PLBW process of mild steel plates with a thickness of 1.8 mm. The predicted weld pool profiles were consistent with the experimental findings. The finding suggested the molten metal, driven by surface tension and recoil pressure, successively generated liquid bridges on the rear and front sides of the pool. The two sheets were joined as the molten metal gradually solidified. The energy absorptivity was highly correlated with the weld pool and keyhole dynamics, and the laser energy absorbed by the metal was mainly transferred in the form of thermal convection. The kinematic features of the melt were observed by the liquid phase mass transfer rate and surface fluctuations. According to the Fourier analysis results, the molten pool oscillated at the characteristic frequency of the laser pulse frequency. The spatial and temporal distributions of solidification parameters aided in analyzing the solidification features within the pool. The asymmetric flow had a greater influence on the temperature gradient. These findings addressed the roles of PLBW on fluid flow, heat behaviors, and solidification parameters of welds with assembly tolerances, as well as the reasons for improved weld formation.