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In the last couple of years, substantial research has been dedicated to studying high-energy short-pulse laser welding. In high energy laser welding, the pulse duration is typically less than the characteristic time of material flow. In addition, their parameter ranges (laser power, energy density and fluence) are rather broad compared to inertial confinement fusion and ion accelerators. However, the understanding of how short pulse laser welding works has been hindered by the complexity of the physics. Furthermore, experimental validations are time consuming and costly.
Our FLOW-3D WELD code simulates the laser welding process from powder spread to weld bead formation. At each time step, it solves the coupled multi-fluid-continuum equations to accurately describe the melt pool dynamics. FLOW-3D WELD can be coupled with physical models to determine heat transfer, material relaxation and gas transport. It also provides comprehensive physical and geometric models of shield gas dynamics, and supports many features to accurately capture the processes at the micro- and meso-scales including the formation of radiation-induced nanocrystals. Finally, the code can be interfaced with our simulations including melt pool dynamics, powder spreading, material flow, pre- and post-processing (e.g. rolling and slitting) and NCAP in the creation of machine-level part files.
To characterize the welding quality and identify the major contributions to the melt pool dynamics, we performed high speed imaging of the actual weld and optimized the weld parameters such as pulse duration, amplitude and repetition rate in the FLOW-3D WELD simulation. We could predict the melt pool shape and formation dynamics (e.g. droplet shrinkage and recoil) and optimize the laser welding processing parameters to limit spatter generation and reduce keyhole flow, thus providing an effective approach to control keyhole dynamics and suppress keyhole instabilities.
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