Modeling and numerical study of keyhole-induced porosity formation in laser beam oscillating welding of 5A06 aluminum alloy

Ke, Wenchao; Bu, Xianzheng; Oliveira, J.P.; Wei, Xu; Wang, Zhimin; Zeng, Zhi

doi:10.1016/j.optlastec.2020.106540

Cited by 115 publications

(18 citation statements)

References 34 publications

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“…In addition, the analysis shows the critical influence of the recoil and the Marangoni force. Yan et al and Khairallah et al [ 29 , 30 , 31 ] have developed a multi-physics field framework to define single/multi-track defects’ creation for the Electron Beam Powder Bed Fusion (E-PBF) system. They observed how energy intake and the depth of the metallic powder particle greatly impacted the balling phenomenon.…”

Section: Introductionmentioning

confidence: 99%

“…They noted that scanning velocity was a crucial parameter correlated strongly with the molten pool measurements and the surface morphology. Zhou et al, Everitt et al, and Tang et al developed a physics-dependent CFD model [ 30 , 31 , 32 ], using the beam-tracing technique. The results reveal that the instability of the melt pool and keyhole triggered the generation of the voids.…”

Section: Introductionmentioning

confidence: 99%

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Full-Field Mapping and Flow Quantification of Melt Pool Dynamics in Laser Powder Bed Fusion of SS316L

Rehman

Pıtır²,

Salamcı

2021

Materials

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Laser powder bed fusion (LPBF) has a wide range of uses in high-tech industries, including the aerospace and biomedical fields. For LPBF, the flow of molten metal is crucial; until now, however, the flow in the melt pool has not been described thoroughly in 3D. Here, we provide full-field mapping and flow measurement of melt pool dynamics in laser powder bed fusion, through a high-fidelity numerical model using the finite volume method. The influence of Marangoni flow, evaporation, as well as recoil pressure have been included in the model. Single-track experiments were conducted for validation. The temperature profiles at different power and speed parameters were simulated, and results were compared with experimental temperature recordings. The flow dynamics in a single track were exposed. The numerical and experimental findings revealed that even in the same melting track, the melt pool’s height and width can vary due to the strong Marangoni force. The model showed that the variation in density and volume for the same melting track was one of the critical reasons for defects. The acquired findings shed important light on laser additive manufacturing processes and pave the way for the development of robust, computational models with a high degree of reliability.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Full-Field Mapping and Flow Quantification of Melt Pool Dynamics in Laser Powder Bed Fusion of SS316L

Rehman

Pıtır²,

Salamcı

2021

Materials

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“…T-joints are an exciting topic for automobile and aerospace manufacturers [5,6], and T-joint welding of medium-thick Al-alloy plates usually require three processes: root, filling, and cover welding [6,7]. However, multi-pass welding would result in defects such as poor fusion quality and low welding efficiency, and these greatly reduce the manufacturing reliability of the components [8]. The dual heat source bilateral synchronous welding technology aimed to improve the welding efficiently and has been successfully applied to mass production for producing lightweight equipment in an energy conservation and emission reduction manner.…”

Section: Introductionmentioning

confidence: 99%

“…The double-sided arc welding process has been adopted to join light metal alloy with improved welding quality in comparison with conventional processes, as reported by Shen et al [5]. Conventional processes in this part are the multi-pass welding, and the double side welding is used to improve the weld efficiency while ensuring that the joint does not have misalignment and complete penetration [8]. The three steps of root, filling, and cover welding for the T-joint welding of 15 mm, 20 mm, and 30 mm 6082-T6 Al-alloy plates with the improved welding efficiency to some extent was reported [22,23], but the process complexity increased.…”

Section: Introductionmentioning

confidence: 99%

Study on Medium-Thick Al-Alloy T-Joints by Dual P-GMAW Bilateral Synchronous Welding

Wang

Zhang

Yan

et al. 2021

Metals

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The T-joints of medium-thick 6082 Al-alloy plates created by dual pulsed gas metal arc welding (P-GMAW) and bilateral synchronous welding were investigated to improve weld quality using the adaptive deposition method, which calculates the minimum amount of deposition according to the welding condition, groove size, and cross-sectional area, effectively reducing the heat input and deformation of the welds on the basis of weld filling. The optimized linear energy with a wire feed speed (WFS) of 9.5 m/min can ensure a well-formed weld with a complete root fusion, and high-quality T-joint welds were obtained both in root openings of 0 mm and 1 mm. The biggest penetration was 4 mm, which was four times more than that of the result from a single torch welding process. When the distance between the two welding torches exceeded 20 mm, the molten pool was completely separated, and process pores were observed in the unfused root zone. Influenced by the thermal cycles in asymmetric welding, the hardness distribution changed: the width of the softer zone at the base plate with the fore arc was smaller than that zone with the rear arc. Furthermore, dual P-GMAW bilateral synchronous welding with an asymmetric heat source can further reduce the deformation of the welded joint by about 20% compared to that of symmetric welding.

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“…This microporosity is of gas and shrinkage nature [ 8 ], which is characteristic for casting of aluminum in general. It is important to note, however, that the skin-thickness laser processing does not allow us to reach the conditions for the evolution and migration of micropores due to the lack of a macroscale molten pool and, then, bulk crystallization process [ 9 ]. The surrounding atmosphere plays a significant role within AA processing that mostly leads to the formation of undesirable phases [ 10 ].…”

Section: Introductionmentioning

confidence: 99%

Formation of Fractal Dendrites by Laser-Induced Melting of Aluminum Alloys

et al. 2021

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We report on the fabrication of fractal dendrites using laser-induced melting of aluminum alloys. We target boron carbide (B4C), which is one of the most effective radiation-absorbing materials characterized by a low coefficient of thermal expansion. Due to the high fragility of B4C crystals, we were able to introduce its nanoparticles into a stabilization aluminum matrix of AA385.0. The high-intensity laser field action led to the formation of composite dendrite structures under the effect of local surface melting. Modelling the dendrite cluster growth confirms its fractal nature and sheds light on the pattern behavior of the resulting quasicrystal structure.

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Modeling and numerical study of keyhole-induced porosity formation in laser beam oscillating welding of 5A06 aluminum alloy

Cited by 115 publications

References 34 publications

Full-Field Mapping and Flow Quantification of Melt Pool Dynamics in Laser Powder Bed Fusion of SS316L

Full-Field Mapping and Flow Quantification of Melt Pool Dynamics in Laser Powder Bed Fusion of SS316L

Study on Medium-Thick Al-Alloy T-Joints by Dual P-GMAW Bilateral Synchronous Welding

Formation of Fractal Dendrites by Laser-Induced Melting of Aluminum Alloys

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