The laser energy absorption on the keyhole wall is decisive for the thermodynamic behavior and the resultant weld properties in the high-power laser beam welding process. Consequently, a realistic implementation of the effect of the laser radiation on the weld metal is crucial to obtain reliable and accurate simulation results. However, its highly transient nature on a microsecond scale makes the quantitative analysis challenging. In this paper, the influence of the relevant welding parameters, e.g. laser power, welding speed and focus position, on the laser energy absorption is studied statistically, namely in a time-averaged manner, by utilizing multi-physical modeling, in which the three-dimensional transient keyhole dynamics and thermo-fluid flow are calculated. The free surface is tracked by the volume-of-fluid algorithm. An advanced ray-tracing method based on a localized Level-Set strategy is employed to consider the underlying laser-material interactions, i.e. the multiple reflections and Fresnel absorption. The results show that the focus position has a remarkable effect on the time-averaged laser absorption, to which more attention should be paid. In contrast, the laser energy distribution regime is only slightly influenced by the welding speed in the studied parameter range between 1.5 m/min and 3 m/min. The comparison between the calculated results and the experimental measurements ensures the validity of the proposed model.
Keywords
- Laser Beam Welding
- Laser Energy Absorption
- Numerical Modeling
- Parametric Study