Numerical modelling of continuous laser welding of S355J2 steel using a volumetric heat source
Aleksander Siwek1
, Sławomir Kąc1, Janusz Pikuła2
1AGH University of Krakow, al. A. Mickiewicza 30, 30-059 Krakow, Poland.
2Łukasiewicz Research Network – Upper Silesian Institute of Technology, ul. Karola Miarki 12–14, 44-100 Gliwice, Poland.
DOI:
https://doi.org/10.7494/cmms.2023.4.0822
Abstract:
Numerical modelling of laser welding requires that numerous strongly coupled physical phenomena be taken into account. A laser is a source of welding heat characterized by the small size of the heating volume and the shape of the fusion zone has a marked impact on the quality of the weld. In this work, a conical heat source was used with geometrical parameters to give the appropriate profile of the fusion line. The use of the weld shape factor and the dependence of the power density on the linear welding energy increases the accuracy of matching the calculated shape of the fusion line. The heat source was tested for the continuous welding case of a sheet made of steel type S355J2. The CFD software ANSYS Fluent was used to calculate the welding model. The temperature field, calculated using the finite volume method, was used to calculate the phase composition and fusion zone profile tracking. The nodes of the model reaching the maximum solidus temperature of S355J2 steel, form the profile of the fusion zone. The laser welding model allows for tracking of the kinetics of phase transformations in the cooling stage. Continuous cooling transformation phase diagram data is loaded for the welded steel grade. The calculation results of the welding model were compared with the weld micrographs.
Cite as:
Siwek, A., Kąc, S., & Pikuła, J. (2023). Numerical modelling of continuous laser welding of S355J2 steel using a volumetric heat source. Computer Methods in Materials Science, 23(4), 45-56. https://doi.org/10.7494/cmms.2023.4.0822
Article (PDF):
Keywords:
Laser welding, Numerical modelling, CFD, Conical heat source, Phase changes in steel
References:
Ai, Y., Jiang, P., Shao, X., Wang, C., Li, P., Mi, G., Liu, Y., & Liu, W. (2016). An optimization method for defects reduction in fiber laser keyhole welding. Applied Physics A, 122, 31. https://doi.org/10.1007/s00339-015-9555-8.
ANSYS 2021/R2 ANSYS (2021). Fluent Theory Guide. ANSYS Inc.
Avrami, M. (1939). Kinetics of phase change. I general theory. Journal of Chemical Physics, 7(12), 1103–1112. https://doi.org/10.1063/1.1750380.
Bag, S., Trivedi, A., & De, A. (2009). Development of a finite element based heat transfer model for conduction mode laser spot welding process using an adaptive volumetric heat source. International Journal of Thermal Sciences, 48(10), 1923–1931. https://doi.org/10.1016/j.ijthermalsci.2009.02.010.
BS-EN 1993-1-2:2005. Eurocode 3: Design of steel structure general rules-structural fire design. European Standard.
Chen, L., Mi, G., Zhang, X., & Wang, C. (2019). Numerical and experimental investigation on microstructure and residual stress of multi-pass hybrid laser-arc welded 316L steel. Materials and Design, 168, 107653. https://doi.org/10.1016/j.matdes.2019.107653.
Dal, M., & Fabbro, R. (2016). An overview of the state of art in laser welding simulation. Optics and Laser Technology, 78(A), 2–14. https://doi.org/10.1016/j.optlastec.2015.09.015.
Esfahani, M.N., Coupland, J., & Marimuthu, S. (2014). Microstructure and mechanical properties of a laser welded low carbon–stainless steel joint. Journal of Materials Processing Technology, 214, 2941–294. https://doi.org/10.1016/j.jmatprotec.2014.07.001.
Farrokhi, F., Endelt, B., & Kristiansen, M. (2019). A numerical model for full and partial penetration hybrid laser welding of thick-section steels. Optics and Laser Technology, 111, 671–686. https://doi.org/10.1016/j.optlastec.2018.08.059.
Goldak, J., Chakravarti, A., & Bibby, M. (1984). A new finite element model for welding, heat sources. Metallurgical Transactions B, 15B, 299–305. https://doi.org/10.1007/BF02667333.
Ha, E.-J., & Kim, W.-S. (2005). A study of low-power density laser welding process with evolution of free surface. International Journal of Heat and Fluid Flow, 26(4), 613–621. https://doi.org/10.1016/j.ijheatfluidflow.2005.03.009.
Han, L., & Liou, F.W. (2004). Numerical investigation of the influence of laser beam mode on melt pool. International Journal of Heat and Mass Transfer, 47(19–20), 4385–4402. https://doi.org/10.1016/j.ijheatmasstransfer.2004.04.036.
Jie, X., & Hui, J. (2018). Numerical modeling of coupling thermal–metallurgical transformation phenomena of structural steel in the welding process. Advances in Engineering Software, 115, 66–74. https://doi.org/10.1016/j.advengsoft.2017.08.011.
Ki, H., Mohanty, P.S., & Mazumder, J. (2002). Modeling of laser keyhole welding: Part I. Mathematical modeling, numerical methodology, role of recoil pressure, multiple reflections, and free surface evolution. Metallurgical and Materials Transactions A, 33A, 1817–1830. https://doi.org/10.1007/s11661-002-0190-6.
Koistinen, D.P., & Marburger, R.E. (1959). A general equation describing extend of austenite-martensite transformation in pure Fe-C alloys and plain carbon steels. Acta Metallurgica, 7(1), 59–60. https://doi.org/10.1016/0001-6160(59)90170-1.
Kumar, A., & DebRoy, T. (2004). Guaranteed fillet weld geometry from heat transfer model and multivariable optimization. International Journal of Heat and Mass Transfer, 47(26), 5793–5806. https://doi.org/10.1016/j.ijheatmasstransfer.2004.06.038.
Laurens, P., Dubouchet, C., Kechemair, D., Coste, F., & Sabatier, L. (1996). Absorption dynamic behaviour of metals during CO2 laser solid state treatments. Journal of Physics D: Applied Physics, 29, 225–232. https://doi.org/10.1088/0022-3727/29/1/033.
Liu, S., Wu, Z., Liu, H., Zhou, H., Deng, K., Wang, C., Liu, L., Li, E. (2023). Optimization of welding parameters on welding distortion and stress in S690 high-strength steel thin-plate structures. Journal of Materials Research and Technology, 25, 382–397. https://doi.org/10.1016/j.jmrt.2023.05.169.
Mollamahmutoglu, M., Yilmaz, O. (2021). Volumetric heat source model for laser-based powder bed fusion process in additive manufacturing. Thermal Science and Engineering Progress, 25, 101021. https://doi.org/10.1016/j.tsep.2021.101021.
Mukherjee, T., De Manvatkar, V., A., & DebRoy, T. (2017). Dimensionless numbers in additive manufacturing. Journal of Applied Physics, 121(6), 064904. https://doi.org/10.1063/1.4976006.
Pyo, C., Kim, J., Kim, Y., & Kim, M. (2022). A study on a representative heat source model for simulating laser welding for liquid hydrogen storage containers. Marine Structures, 86, 103260. https://doi.org/10.1016/j.marstruc.2022.103260.
Rosenthal, D. (1941). Mathematical theory of heat distribution during welding and cutting. Welding Journal, 20, 220–234.
Safdar, S., Pinkerton, A.J., Li, L., Sheikh, M.A., & Withers, P.J. (2013). An anisotropic enhanced thermal conductivity approach for modelling laser melt pools for Ni-base super alloys. Applied Mathematical Modelling, 37(3), 1187–1195. https://doi.org/10.1016/j.apm.2012.03.028.
Sahoo, R., Debroy, T., & McNallan, M.J. (1988). Surface tension of binary metal – surface active solute systems under conditions relevant to welding metallurgy. Metallurgical Transactions B, 19B, 483–491. https://doi.org/10.1007/BF02657748.
Semak, V., & Matsunawa, A. (1997). The role of recoil pressure in energy balance during laser materials processing. Journal of Physics D: Applied Physics, 30(18), 2541–2552. https://doi.org/10.1088/0022-3727/30/18/008.
Semak, V.V., Steele, R.J., Fuerschbach, P.W., & Damkroger, B.K. (2000). Role of beam absorption in plasma during laser welding. Journal of Physics D: Applied Physics, 33(10), 1179–1185. https://doi.org/10.1088/0022-3727/33/10/307.
Siwek, A. (2021). CFD-based modelling of phase transformation in laser welded low-carbon steel. Welding in the World, 65, 1403–1414. https://doi.org/10.1007/s40194-021-01130-2.
Tsai, N.S., & Eagar, T.W. (1985). Distribution of the heat and current fluxes in gas tungsten arcs. Metallurgical Transactions B, 16B, 841–846. https://doi.org/10.1007/BF02667521.
Wu, C.S., Wang, H.G., & Zhang, Y.M. (2006). A new heat source model for keyhole plasma arc welding in FEM analysis of the temperature profile. Welding Journal, 85, 284–291.
Wu, C.S., Hu, Q.X., & Gao, J.Q. (2009). An adaptive heat source model for finite-element analysis of keyhole plasma arc welding. Computational Materials Science, 46(1), 167–172. https://doi.org/10.1016/j.commatsci.2009.02.018.
Yan, S., Meng, Z., Chen, B., Tan, C., Song, X., & Wang, G. (2022). Prediction of temperature field and residual stress of oscillation laser welding of 316LN stainless steel. Optics and Laser Technology, 145, 107493. https://doi.org/10.1016/j.optlastec.2021.107493.
Zhang, W., Kim, C.-H., & DebRoy, T. (2004). Heat and fluid flow in complex joints during gas metal arc welding – Part I: Numerical model of fillet welding. Journal of Applied Physics, 95(9), 5210–5219. https://doi.org/10.1063/1.1699485.