A multiscale approach for modeling metal laser welding

Abstract

The growing application of laser welding in the industry motivates the development of computational models to help improve and understand the details of the laser welding process. Classical molecular dynamic (MD) or finite element (FE) methods are insufficient to model the process due to several limitations. The coupling of both methods provides a unique approach for modeling the laser welding process. A laser welding model that accounts for free-electron conduction and three-dimensional laser beam growth was developed on the basis of this coupling. The model was tested on a Cu sample, and the results showed that the amount of energy required to weld the interface was much lower than the energy used in previous studies of MD laser processes. The temperatures in the weld pool and the heat-affected zones were similar to those in previous FE studies. The crystal structure near the weld pool matched the observations of the previous MD studies. Moreover, the scanning speeds associated with this model were relatively higher than those of previous MD models due to the effects of fast electron conduction.

Integrated Computational Materials Engineering for Advanced Automotive Technology: With Focus on Life Cycle of Automotive Body Structure

“…[150] Badawy and Syarif proposed a combined discrete classical MD and continuum FEM while considering free-electron conduction during laser welding and energy transfer from the electron to the lattice after laser welding. [151] Herrnring et al presented a multiscale modeling approach that integrated a phenomenological material model that accounted for the change from the fluid to the solid phase, and the Kampmann-Wagner numerical model considering the kinetics of the precipitates. [152] The integrated computational model was implemented in the FEM and predicted the residual stresses of the laser-beam-welded precipitationhardened aluminum alloy AA6082-T6.…”

Innovations in Monitoring, Control and Design of Laser and Laser-Arc Hybrid Welding Processes

“…The experimental results well verified the theoretical prediction. Badawy et al [109] proposed a method combining classical molecular dynamics (MD) or finite element (FE) methods to develop metal laser welding model. The results show that the multi-scale model of metal laser welding is obtained by coupling continuous finite element method and discrete classical MD.…”