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Numerical analysis of static and dynamic heat source model approaches in laser micro spot welding

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Abstract

In this work, a transient three-dimensional finite element model (FEM) of the laser micro spot welding (LMSW) process was established considering three heat source approaches: static heat source model (SHSM), dynamic heat source model (DHSM), and double dynamic heat source model (DDHSM). Each model was computed according to the aspect ratio of spot width to depth and the absorptance of the material. The numerical simulation computed the conduction-to-keyhole transition using an AISI 302 stainless steel alloy. Our results showed that the DDHSM results were based on the experiments reported in the literature. The conduction-to-keyhole transition for the SHSM and DHSM was observed to depend on the average laser power, having a constant keyhole aperture at 75 ms exposure time and 220 W average laser power. Additionally, the DDHSM configuration gave a conduction-to-keyhole transition with a similar constant aperture at 75 and 50 ms of exposure time for 200 and 220 W average laser power, respectively. The percentage errors for the DDHSM were 8%, 15%, 17%, and 20% for the penetration depth, top, middle, and bottom width, respectively.

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Data availability

The datasets generated and analyzed during the current study are available from the corresponding author upon reasonable request.

Abbreviations

A :

Cross-sectional area, mm2

Ab :

Absorptance of the material, %

Cp :

Specific heat capacity, J/kg°C

h :

Melt pool’s penetration depth, µm

k :

Thermal conductivity, W/m2°C

N :

The normal vector of the surfaces

q :

Localized heat flux, \({\text{W}}/{{\text{m}}}^{2}\)

R :

Electrical resistivity, \(\mathrm{\mu \Omega cm}\)

T :

Temperature, \(^\circ{\rm C}\)

t :

Exposure time, \({\text{s}}\)

V :

Melt pool volume, \({{\text{mm}}}^{3}\)

z :

Distance from the top surface of the substrate, \({\text{mm}}\)

h K :

Keyhole’s penetration depth, \(\mathrm{\mu m}\)

h c :

Heat convection transfer coefficient, \({\text{W}}/{{\text{m}}}^{2}\mathrm{^\circ{\rm C} }\)

H LMSW :

Welding heat source, \({\text{J}}\)

H p :

Specific heat required, \({\text{J}}/{{\text{mm}}}^{3}\)

k n :

Thermal conductivity normal to the surface, \({\text{W}}/{{\text{m}}}^{2}\mathrm{^\circ{\rm C} }\)

L F :

Latent heat of fusion, \({\text{J}}/{\text{kg}}\)

T O :

Initial temperature, \(^\circ{\rm C}\)

T M :

Melting temperature, °C

TB :

Boiling temperature, °C

tCK :

Time to close keyhole, s

t OK :

Time to open keyhole, s

P AVG :

Average laser power, W

Q in :

Heat input transferred, J

Q surf :

Circular heat surface, \({\text{J}}\)

Q vol :

Cylindrical heat volume, \({\text{J}}\)

W T :

Top width, \(\mathrm{\mu m}\)

W M :

Middle width, \(\mathrm{\mu m}\)

W B :

Bottom width, \(\mathrm{\mu m}\)

λ :

Laser beam’s wavelength, \({\text{nm}}\)

κ :

Thermal diffusivity, \({{\text{mm}}}^{2}/{\text{s}}\)

ρ :

Density of the material, \({\text{kg}}/{{\text{m}}}^{3}\)

η C :

Coupling efficiency, \(\%\)

Φ O :

Laser spot diameter at the focal plane, \(\mathrm{\mu m}\)

Φ B :

Laser spot diameter or heating surface diameter, \(\mathrm{\mu m}\)

Φ H :

Heating volume diameter, \(\mathrm{\mu m}\)

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Funding

This research was funded by Tecnologico de Monterrey through the Research Unit of Accelerated Materials Discovery of the Institute of Advanced Materials for Sustainable Manufacturing. The characterizations were performed in the National Lab in Additive Manufacturing, 3D Digitizing and Computed Tomography (MADiT) LN-314934.

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Authors and Affiliations

  1. Institute of Advanced Materials for Sustainable Manufacturing (IAMSM), Tecnologico de Monterrey, Av. Eugenio Garza Sada 2501 Sur, NL, Monterrey, 64849, México

    Rigoberto Guzmán-Nogales, Luis D. Cedeño-Viveros & Alex Elías-Zúñiga

  2. Escuela de Ingeniería y Ciencias, Tecnologico de Monterrey, Ave. Eugenio Garza Sada 2501, 64849, Monterrey, NL, México

    Erika García-López, Ciro A. Rodríguez, Luis D. Cedeño-Viveros & Alex Elías-Zúñiga

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  1. Rigoberto Guzmán-Nogales
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  4. Luis D. Cedeño-Viveros
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Guzmán-Nogales, R., García-López, E., Rodríguez, C.A. et al. Numerical analysis of static and dynamic heat source model approaches in laser micro spot welding. Int J Adv Manuf Technol (2024). https://doi.org/10.1007/s00170-024-13645-1

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