Prediction of Weld Joint Shape and Dimensions in Laser Welding Using a 3D Modeling and Experimental Validation

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.