Molten pool characterization of laser lap welded copper and aluminum

Xue, Zhiqing; Hu, Shengsun; Zuo, Di; Cai, Wayne; Lee, Dong-Kyun; Elijah, Kannatey Asibu

doi:10.1088/0022-3727/46/49/495501

Cited by 33 publications

(10 citation statements)

References 26 publications

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“…Therefore, the mass transport of dissimilar metals increases, resulting in an increase in the thickness of the intermetallic reaction layer. As stated by Hu et al [11] and Yu et al [12], if the thickness of the intermetallic reaction layer is excessively large, intermetallic compounds may be produced to attenuate joint performance [24][25][26][27][28]. In addition, excessive Ti in the weld beam is also not conducive to welding quality.…”

Section: Mass Transfermentioning

confidence: 99%

3D Multiphysical Modelling of Fluid Dynamics and Mass Transfer in Laser Welding of Dissimilar Materials

Jiazhou

Zhang

Feng

et al. 2018

Metals

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Abstract:A three-dimensional multiphysical transient model was developed to investigate keyhole formation, weld pool dynamics, and mass transfer in laser welding of dissimilar materials. The coupling of heat transfer, fluid flow, keyhole free surface evolution, and solute diffusion between dissimilar metals was simulated. The adaptive heat source model was used to trace the change of keyhole shape, and the Rayleigh scattering of the laser beam was considered. The keyhole wall was calculated using the fluid volume equation, primarily considering the recoil pressure induced by metal evaporation, surface tension, and hydrostatic pressure. Fluid flow, diffusion, and keyhole formation were considered simultaneously in mass transport processes. Welding experiments of 304L stainless steel and industrial pure titanium TA2 were performed to verify the simulation results. It is shown that spatters are shaped during the welding process. The thickness of the intermetallic reaction layer between the two metals and the diffusion of elements in the weld are calculated, which are important criteria for welding quality. The simulation results correspond well with the experimental results.

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Section: Mass Transfermentioning

confidence: 99%

3D Multiphysical Modelling of Fluid Dynamics and Mass Transfer in Laser Welding of Dissimilar Materials

Jiazhou

Zhang

Feng

et al. 2018

Metals

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“…Therefore, the laser welding of titanium and nickel alloys has been of growing interest for industrial applications, most notably in the aerospace industry, where it can be used to manufacture parts destined for high-temperature regions of the engine and turbine [5,6]. Recently, the dissimilar welding process has attracted more attention in light of its economic benefits and design flexibility, offering the possibility of applying optimal material to critical locations [7]. Nevertheless, the use of dissimilar welding in place of similar welding requires challenging concerns that arise for two important reasons: the different thermo-physical properties of the base materials can affect heat transfer in the weld pool; the mixing process in the weld pool changes its composition, with consequences visible in both the heat transfer and fluid flow [8].…”

Section: Introductionmentioning

confidence: 99%

“…Esfahani et al [24] developed a 3D multiphase computational fluid model to investigate the melted pool fluid dynamics and alloy composition in a dissimilar laser welding of low carbon steel and stainless steel. Xue et al [7] studied weld pool characterization in a dissimilar laser welding of a Cu-Al lap joint using a 3D finite volume model. They calculated the weld pool temperature distribution, velocity field, and alloying distribution in the weld pool.…”

Section: Introductionmentioning

confidence: 99%

Numerical modeling of fluid flow, heat, and mass transfer for similar and dissimilar laser welding of Ti-6Al-4V and Inconel 718

Faraji

Maletta

Barbieri

et al. 2021

Int J Adv Manuf Technol

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Most of the researches published on the numerical modeling of laser welding are looking at similar welding, mainly due to the difficulty of simulating the mixing phenomenon that occurs in dissimilar welding. Furthermore, numerical modeling of dissimilar laser welding of titanium and nickel alloys has been rarely reported in the literature. In this study, a 3D finite volume numerical model is proposed to simulate fluid flow, heat, and mass transfer for similar and dissimilar laser welding of Ti-6Al-4V and Inconel 718. The laser source was simulated by volumetric heat distribution, which considers the effects of keyhole and heat transfer on the workpiece. The heat source parameters were calibrated through preliminary experiments, by comparing the simulated and experimental weld pool shapes and dimensions. The model was used to simulate both homogenous and dissimilar laser weldings of Ti-6Al-4V and Inconel 718, and a systematic comparison was carried out through a number of selected experiments. The effects of three distinct levels of laser power (1.25 kW, 1.5 kW, 2.5 kW) on temperature distribution and velocity field in the welds pool were analyzed. Results highlighted the effects of Marangoni forces in the weld pool formation. Furthermore, in order to analyze the mass transfer phenomenon in dissimilar welding, species transfer equations were considered, demonstrating the important role played by the mass mixture in the weld pool formation. Finally, a high level of agreement between simulations and experiments—in terms of weld pool shape and dimensions—was observed in all cases analyzed. This proves the ability of the proposed numerical model to properly simulate both the similar and dissimilar welding of Ti-6Al-4V and Inconel 718 alloys.

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“…Dissimilar joints of aluminium and copper show great advantages in electrical applications owing to their higher electrical and heat conductivities, corrosion resistance and mechanical properties [1][2][3][4]. However, some defects can occur when using conventional fusion welding methods, such as brittle intermetallic compounds (IMC) and pores, due to the different thermal, chemical and mechanical properties of the metals [5][6][7]. Due to the inefficiency and complicacy of fusion welding methods, more and more studies are focused on alternate welding methods, such as solidstate welding including explosive welding and brazing.…”

Section: Introductionmentioning

confidence: 99%

Effect of Shoulder Diameter on the Force Generation, Microstructure and Mechanical Properties of Friction Stir-Brazed Aluminium Alloy and Copper with Ultrahigh Rotation Speed

Zhou

Chen

Wang

et al. 2019

Acta Metall. Sin. (Engl. Lett.)

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Friction stir brazing with ultrahigh rotation speed was applied to 6061 aluminium alloy-pure copper lap joints with the aid of zinc foil. The effects of different shoulder diameters from 7 to 15 mm on the microstructure and mechanical properties of Al/Cu FSB joints were investigated along with the temperature and resistance of the friction tool. The oscillation of forward resistance and lateral force was related to the flow of the plastic metal and contributed to obtain a good appearance during the welding process. From the appearance of the welded joints, it was obvious that the phase difference between the forward resistance and lateral force had a significant influence on the joint characteristics. Obvious scale-like ripples appeared on the weld area when a sharp angle in the phase difference curve existed. Additionally, with a lower axial force and oscillation assistance, a satisfactory joint could be obtained. The results of the shear strength of the brazed joint showed that the shoulder with a 12 mm diameter yielded the highest shear strength. Meanwhile, the zinc foil in the middle melted completely and formed finely dispersed CuZn 5 Al-Zn eutectic structures at the Al-Cu interface.

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Molten pool characterization of laser lap welded copper and aluminum

Cited by 33 publications

References 26 publications

3D Multiphysical Modelling of Fluid Dynamics and Mass Transfer in Laser Welding of Dissimilar Materials

3D Multiphysical Modelling of Fluid Dynamics and Mass Transfer in Laser Welding of Dissimilar Materials

Numerical modeling of fluid flow, heat, and mass transfer for similar and dissimilar laser welding of Ti-6Al-4V and Inconel 718

Effect of Shoulder Diameter on the Force Generation, Microstructure and Mechanical Properties of Friction Stir-Brazed Aluminium Alloy and Copper with Ultrahigh Rotation Speed

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