CFD and FEM Analysis of Laser Weld Shape and its Characteristic

M Sundar, R Eghlio and L Li

Laser Processing Research Centre, School of Mechanical, Aerospace and Civil Engineering
1. Introduction
Laser butt welding simulation has been performed by many researchers in the past and in all previous simulations, the
surface of the weld bead is assumed to be perfectly flat which is a crude assumption. In this work a coupled thermo-structural
analysis was carried out with an objective to predict the effect of laser parameters on change in surface topology of the weld
bead and also its subsequent effect on thermal and structural results. The numerical simulation results agree well with the
experimental results conducted on a mild steel sheet using a 1 kWfibre laser.
2. Formulation
The 3D CFD analysis was performed incorporating Navier-
Stokes mass, energy and momentum equations. Heat input
is modelled as a Gaussian volumetric heat source and heat
loss is due to convection and radiation in the surfaces. The
weld surface topological changes are primarily due to the
fluid flow in the weld pool, which is driven by combined
surface tension and buoyancy force. The FEM
investigation makes use of the modified weld bead surface
4. FEM Results
(a) (b)
Speed = 75 mm/s
Speed = 100 mm/s
Speed = 125 mm/s
0.0E+00
5.0E+07
1.0E+08
1.5E+08
2.0E+08
2.5E+08
3.0E+08
-2 -1.5 -1 -0.5 0 0.5 1 1.5 2
S
t
r
e
s
s

(
P
a
)
Distance (mm)
Speed = 75 mm/s Speed = 100 mm/s Speed = 125 mm/s
investigation makes use of the modified weld bead surface
geometry and the temperature history predicted by the CFD
analysis. To understand the effect of bead geometry on the
tensile strength characteristics of the welds, a non-linear
finite element analysis incorporating multilinear isotropic
hardening was performed.
3. CFD Results
6. Discussion
At low weld speeds, the molten pool on the surface flows
outwards causing a depression in the weld pool centre and
at high speeds, the molten pool flows inward causing a
humped weld and at some particular welding speed there
is minimum melt flow due to close to zero surface tension
Figure 1: Different weld bead top surface profiles for 600 W laser power
and speed: a) 75 mm/s, b) 100 mm/s, c) 125 mm/s
(a) (b) (c)
Figure 2: Comparison of experimental (left side) and simulated (right side) weld
(a) (b) (c)
Figure 4: Comparison of residual stress for difference welding conditions
a) along the cross section b) across the weld bead surfaces
(a) (b)
Figure 5: Comparison of experimental and simulated tensile test results
for a speed of : a) 75 mm/s, b) 100 mm/s, c) 125 mm/s
(a) (b) (c)
5. Tensile Test Results
Weld line
Failure zone
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2
2
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-
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1
7
1
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1
2
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7
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7. Conclusions
The CFD simulation effectively predicts and paves way to control the weld bead surface geometry. CFD modelling has
shown the main reason for the different weld bead surface geometry formation as the Marangoni effect with flipping
surface tension gradient signs as the melt pool temperature changes. In FEM analysis the net-shape weld shows smooth and
minimal stress distribution also, it shows better tensile test performance largely due to the lack of stress concentrators at the
weld zones which is also the case in experimentation.
is minimum melt flow due to close to zero surface tension
gradients. The FEM results show relatively smaller and
smoother residual stresses for net shape welding shape,
possibly due to reduced heat input to the material. In the
tensile test simulation the net shaped weld, shows high
distortion away from the welding zone because of its flat
surface geometry shifting and spreading the stress
concentration to places away from the weld zones.
Figure 2: Comparison of experimental (left side) and simulated (right side) weld
bead cross section profiles for a speed of: a)75 mm/s, b)100 mm/s, c)125 mm/s
Figure 3: Comparison of top surface velocity vector for 600 W laser power
and speed: a) 75 mm/s, b) 100 mm/s, c) 125 mm/s
(a) (b) (c)