Numerical simulation of heat transfer and fluid flow during double-sided laser beam welding of T-joints for aluminum aircraft fuselage panels

Yang, Zhibin; Wang, Tao; Li, Liqun; Chen, Yanbin; Shi, Chunyuan

doi:10.1016/j.optlastec.2016.12.018

Cited by 42 publications

(6 citation statements)

References 43 publications

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“…The lack of plume heating in the modeling will lead to the mismatch between the simulated molten pool width and the experimental molten pool width. As suggested by Yang et al [24], two additional surface heat sources are applied on the top and bottom surfaces of the workpiece to equivalent plume heating effect. And the heat flux satisfies the following equation:…”

Section: Heat Source Modelmentioning

confidence: 99%

Effect of welding heat input conditions on the dynamic behavior of pulse laser beam welding molten pool for Ti6Al4V thin plate with clearance

Kong

Wei

Tang

et al. 2022

Int J Adv Manuf Technol

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For a practical pulse laser beam welding (PLBW) process of metal sheets assembled in butt joint configuration, the precise control of the assembling clearance has been a challenge. The existence of machining burrs and assembly errors will lead to forming severe defects, such as misalignment, welding leakage, and penetrating. In this paper, a pair of Ti6Al4V plates with a 0.2 mm air gap was tested by an improved PLBW process. A three-dimensional multi-phase and multi-physical field coupling model of Ti6Al4V alloy plate with a reserved air gap was established according to the weld profile, and the dynamic behavior of the keyhole and molten pool was simulated. Transient temperature field, velocity field, keyhole size, and liquid bridge connection were calculated by using different welding heat input parameters. The results showed that the weld profile simulated by the CFD model is in good agreement with the experimental results, and the deviation is between 0.68% and 7.95%. After the laser power reaches the peak value, the metal steam eruption weakens and the obvious Marangoni vortex appears in the molten pool. The simulated keyhole is always in three stages, that is, the keyhole appears, and then gradually forms the through-hole. The through hole keeps oscillating, and finally, the keyhole shrinks and disappears when the laser power drops to zero. With the increase of laser peak power, the keyhole shape becomes more curved, indicating that the keyhole oscillation is enhanced. With the increase in welding speed, the stability of the molten pool is improved, and the area of the liquid bridge rises more regularly.

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Section: Heat Source Modelmentioning

confidence: 99%

Effect of welding heat input conditions on the dynamic behavior of pulse laser beam welding molten pool for Ti6Al4V thin plate with clearance

Kong

Wei

Tang

et al. 2022

Int J Adv Manuf Technol

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“…Currently, the research on welding numerical simulation at home and abroad mainly focuses on the numerical simulation of thin plate welding, T-joints, thin small steel pipes, or the numerical simulation of welding for some new materials [9][10][11]. In the process of pressure vessel production, Q345R, as a widely used pressure vessel steel, is a kind of low alloy structural steel.…”

Section: Introductionmentioning

confidence: 99%

A new test for evaluating crack sensitivity of materials during welding

Gao¹,

Li²,

Fan³

et al. 2023

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A new test was developed to evaluate the cracking sensitivity of thick plates based on the strong constraint conditions during the welding process. A typical application of the new test on assessing the cracking sensitivity of Q345R container steel was also investigated. The surface crack rate (δ) and the cross-section crack rate (ζ) both increased when setting the gap narrower. Crack rate and crack length both increased with increasing restraint stress. Under the critical constraint stress, the experimental results show that the welding heat input has no significant effect on crack sensitivity. With increasing carbon equivalent, the crack length and crack rate both increased. The aggregation of S and P was found near the crack, and the oxygen content was high. The fracture showed the characteristics of dendrites and microcrack, which was approved as a solidification crack.

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“…As a unique welding technology, laser welding has the advantages of high energy density and small welding deformation [1][2][3]. The laser welding technology is widely used in many fields, such as aerospace, automobile manufacturing, shipbuilding, and others [4][5][6]. Aluminum alloys have the characteristics of high thermal conductivity and low surface tension [7].…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation of Molten Pool Dynamics in Laser Deep Penetration Welding of Aluminum Alloys

Jin

Yang

et al. 2022

Crystals

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In this paper, the numerical simulation of molten pool dynamics in laser deep penetration welding of aluminum alloys was established based on the FLUENT 19.0 software. The three-dimensional transient behavior of the keyhole and the flow field of molten pool at different welding speeds were analyzed, and the influence of the welding speed on the molten pool of aluminum alloys in laser welding was obtained. The results indicated that the generation of welding spatters was directly related to the fluctuation of the diameter size in the middle of the keyhole. When the diameter in the middle of the keyhole increased by a certain extent, welding spatters occurred. When welding spatters occurred, the diameter in the middle of the keyhole became smaller. In addition, the size of the spatters at the welding speed of 9 m/min was larger than that of the spatters at the welding speeds of 3 m/min and 6 m/min. The welding spatter formed in laser deep penetration welding included: spatter created by an inclined liquid column behind the keyhole; splash created by a vertical liquid column behind the keyhole; small particles splashed in front of the keyhole. With the increase of the welding speed, the tendency of the welding spatter to form in front of the keyhole and to form a vertical liquid column behind the keyhole became weaker. When the welding speed was 9 min, only an obliquely upward liquid column appeared on the molten pool surface behind the keyhole. Compared with the welding speeds of 6 m/min and 9 m/min, the maximum flow velocity fluctuation of the molten pool at the welding speed of 3 m/min was obviously higher.

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Numerical simulation of heat transfer and fluid flow during double-sided laser beam welding of T-joints for aluminum aircraft fuselage panels

Cited by 42 publications

References 43 publications

Effect of welding heat input conditions on the dynamic behavior of pulse laser beam welding molten pool for Ti6Al4V thin plate with clearance

Effect of welding heat input conditions on the dynamic behavior of pulse laser beam welding molten pool for Ti6Al4V thin plate with clearance

A new test for evaluating crack sensitivity of materials during welding

Numerical Simulation of Molten Pool Dynamics in Laser Deep Penetration Welding of Aluminum Alloys

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