Numerical simulation of laser beam welding using an adapted intensity distribution

Liebl, S.; Stadter, Christian; Ganser, Andreas; Zaeh, Michael F.

doi:10.2351/1.4983235

Cited by 12 publications

(4 citation statements)

References 9 publications

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“…The proximity to the top of the molten pool diminishes the alpha angle and enlarges the M value. Accordingly, the molten pool solidification growth rate degrades from the surface to the bottom [39]。From the bottom to the top, the angles of M and V are taken to be 75°, 45°and 15°respectively for computation. The temperature gradient D is determined by model computation, as shown in Fig.…”

Section: Laser Cladding Experiments In Different Working Modesmentioning

confidence: 99%

Single-channel multilayer forming mechanism of laser cladding Fe60 process under different laser heat source working mode

Li,

Sun,

Zhao

et al. 2023

Preprint

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Continuous wave (CW) and pulsed wave (PW) are the two principal modes of working to control the laser heat source. Different laser heat source working modes have an essential impact on the rapid cooling and heating temperature change rate during the cladding, which directly determines the cladding layer quality. The laser cladding process is meaningful to quantitatively reveal the mechanism of single-channel multilayer cladding and forming under different laser heat source working modes. In this paper, a multi-field coupled 3D numerical model of the single-channel multilayer cladding process under diverse laser working modes is proposed, and the thermal physical parameters of the cladding material are computed on the basis of CALPHAD method. The mechanism of the impact of distinct working modes on the multi-field coupled ephemeral evolution process of laser cladding is investigated by using the solid/liquid interface tracking technique, which comprehensively considers the light-powder interaction between the powder waist beam and the laser beam in diverse working modes. The temperature, flow and stress fields are computationally solved for a single-channel multilayer cladding process. On the foundation of this study, the mechanism of the impact of pulse duty cycle and pulse frequency on the cladding behavior of single-channel and multi-layers during pulsed laser cladding was dissected. The macroscopic morphology and microstructure of the cladding layer were observed by KEYENCE VH-Z100R ultra-deep field electron microscope, and the feasibility of the model was confirmed. This study provides an important theoretical rationale for enhancing the cladding quality under different laser working modes.

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Section: Laser Cladding Experiments In Different Working Modesmentioning

confidence: 99%

Single-channel multilayer forming mechanism of laser cladding Fe60 process under different laser heat source working mode

Li,

Sun,

Zhao

et al. 2023

Preprint

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show abstract

“…A solution to reduce this seam defect may be an improved clamping device, which allows the material to post-flow. Another possibility can be the use of an adapted laser intensity profile to reduce the heat gradient [42].…”

Section: Characteristics Of the Mechanical Strengthsmentioning

confidence: 99%

Laser welding of current collector foil stacks in battery production–mechanical properties of joints welded with a green high-power disk laser

Grabmann

Kriegler

Harst

et al. 2021

Int J Adv Manuf Technol

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The qualification of production systems that enable reliable and stable production processes is a major challenge in manufacturing large-format lithium-ion batteries. During cell assembly, the electrode sheets of the anode and the cathode are stacked, and are electrically contacted by a welding process. It was shown that laser beam welding employing a beam source in the green wavelength range is a promising joining approach in terms of high productivity. Therefore, the influence of the process parameters, such as the laser power, the welding speed, the pulse frequency, and the pulse duration, on the weld seam quality was investigated. Particular emphasis was placed on the mechanical strength of the weld seam. Statistically planned experiments were used to determine feasible parameter sets for welding the most common current collectors of lithium-ion battery electrodes, copper (Cu), and aluminum (Al). The influence of the individual process parameters on the tensile shear force was evaluated. Stacks of 40 metal foils were welded with a thin metal sheet in lap joint configuration. Based on an analysis of the requirements for minimum mechanical seam strengths, this study confirms that laser beam welding using a green high-power disk source is an auspicious process for the internal contacting of lithium-ion batteries.

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“…The aluminum layer is based on the temperature-dependent material model developed by [41]. The temperature-dependent modeling is required here since the aluminum heats up from the initial temperature of approx.…”

Section: Structure Of the Modelmentioning

confidence: 99%

A Holistic, Model-Predictive Process Control for Friction Stir Welding Processes Including a 1D FDM Multi-Layer Temperature Distribution Model

Meyer

Fuderer

Zaeh

2021

Metals

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Friction press joining is an innovative joining process for bonding plastics and metals without additives in an overlap configuration. This paper presents for the first time a model-based approach for designing a multi-variable model predictive control (MPC) for friction press joining. For system modeling, a differential equation based on the heat flows was proposed and modeled as a torque-dependent function. With this model, it is possible to consider cross-effects between the axial force and the friction zone temperature. With this theoretical approach, adaptive model-predictive process control was implemented and validated for different material combinations (EN AW-6082-T6; EN AW-2024-T3; PE-HD; PA6-GF30; PPS-CF). It could be shown that the MPC has excellent control accuracy even when model uncertainties are introduced. Based on these findings, a 1D Finite Differential Method multi-layer model was developed to calculate the temperature in the plastic component, which is not measurable in situ (r = 0.93). These investigations demonstrate the high potential of the multi-variable MPC for plastic-metal direct joining.

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Numerical simulation of laser beam welding using an adapted intensity distribution

Cited by 12 publications

References 9 publications

Single-channel multilayer forming mechanism of laser cladding Fe60 process under different laser heat source working mode

Single-channel multilayer forming mechanism of laser cladding Fe60 process under different laser heat source working mode

Laser welding of current collector foil stacks in battery production–mechanical properties of joints welded with a green high-power disk laser

A Holistic, Model-Predictive Process Control for Friction Stir Welding Processes Including a 1D FDM Multi-Layer Temperature Distribution Model

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