The effects of multiple internal reflections within a laser weld joint as functions of joint geometry and processing conditions have been characterized. A computer-based ray tracing model is used to predict the reflective propagation of laser beam energy focused into the narrow gap of a metal joint for the purpose of predicting the location of melting and coalescence to form a weld. Quantitative comparisons are made between simulation cases. Experimental results are provided for qualitative model validation. This method is proposed as a way to enhance process efficiency and design laser welds which display deep penetration and high depth-to-width aspect ratios without high powered systems or keyhole mode melting.

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Nanonal Latmraiq. an affirmative a & d Research and Oevelopment Agrewnenl (CRAOA) between Los iuamai Natmnal of Energy m f c?ntnU W-7405ENG-36 Tta doa*menU the techr*cal u w i n (1B7 Ea3&mnFQmt1M This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, pnxxss, or service by trade name, trademark, manufacturer. or otherwise does not necessarily constitute or imply its endorsement, m mmendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect thosc of the United States Government or any agency thereof.

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