Experimental Validation of a Laser Heat Source Model for Laser Melting and Laser Cladding Processes

Tseng, Wei-Ming; Aoh, Jong-Ning

doi:10.2174/1874155x01408010370

Cited by 4 publications

(1 citation statement)

References 31 publications

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“…Heat source models can either be applied to a single surface of the geometry or to the entire volumetric domain depending on the welding process and the associated heat flux distribution. Often, the heat source model is selected depending on the type of welding process used and for some cases, two or more models are superimposed [10]- [12]. This is required to model complex flux distributions present in Electron Beam Welding (EBW) and in keyhole laser welding.…”

Section: Introductionmentioning

confidence: 99%

An automated inverse method to calibrate thermal finite element models for numerical welding applications

Walker

Bennett

2019

Journal of Manufacturing Processes

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Numerical modelling of welding processes is often completed using a sequentially coupled FE thermo-mechanical analysis to predict both the thermal and mechanical effects induced by the process. The accuracy of the predicted residual stresses and distortions are highly dependent upon an accurate representation of the thermal field. Utilising this approach, the physics of the melt pool are replaced with a heat source model which represents the heat flux distribution of the process. Many heat source models exist; however, the parameters which define the geometrical distribution have to be calibrated using experimental data. Currently the most common method involves trial and error, until the predicted thermal history and melt pool geometry accurately represent the experimental data. Although this is a simple approach, it is often time dependant and inherently inaccurate. Therefore, this study presents an automated calibration process, which determines the optimum element size for the FE mesh and then refines the parameters of the heat source model using an inverse approach. The proposed procedure was implemented for laser beam welding, operating in both the conductive and keyhole regimes. To ensure that both the thermal history data and melt pool geometry were predicted with accuracy, a multi-objective optimisation was required. The proposed methodology was experimentally validated through welding nine IN718 samples using a Nd:YAG laser heat source. A good correlation between the experimental and numerical data sets were apparent. With regards to the predicted melt pool geometry, the maximum error for the width, depth and area of the melt pool was 8.4%, 4.0% and 11.0% respectively. The minimum error was 1.5%, 0.3% and 0.3% respectively. For the temperature profiles, the maximum and minimum error for the peak temperature was 8.6% and 1.2%. Overall, the proposed calibration procedure allows automation of an

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Section: Introductionmentioning

confidence: 99%

An automated inverse method to calibrate thermal finite element models for numerical welding applications

Walker

Bennett

2019

Journal of Manufacturing Processes

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Effect on properties of nickel alloy with the addition of iron and magnesium oxide by gas cladding method

Sudhar Vizhi,

Gadudasu,

Joseph John Marshal

et al. 2024

Materials Today: Proceedings

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State-of-the-art review on laser cladding process as an in-situ repair technique

Raj

Maity

Das

2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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The present work reviews the laser cladding process as a repairing technique and the conventional repairing techniques and different heat source models. In this review work, the authors have tried to address the various traditional methods studied for repairing and surface modification. The dominantly used heat source model for numerical modelling of the repairing techniques and the mechanism of the laser cladding process, along with its advantages over the conventional repairing techniques, is also reviewed. This paper also focuses on the predominantly used laser of high power for the cladding process and the effect of process parameters on the quality of the clad layer. The different materials used as clad materials for repairing purposes during the laser cladding process have also been discussed briefly. In this paper, the authors have surveyed literature from different regions of the globe and considered the literature since 1969. This review discusses the various conventional repairing techniques used for repairing, heat source model, process parameters, and different materials used in the laser cladding process. The authors have also briefed the advantages, disadvantages, and application in each of the sections. The use of laser cladding for in-situ repairing process, development of a precise model, use of low-power laser, and application of laser cladding for actual engineering components was also considered in future research work.

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Experimental Validation of a Laser Heat Source Model for Laser Melting and Laser Cladding Processes

Cited by 4 publications

References 31 publications

An automated inverse method to calibrate thermal finite element models for numerical welding applications

An automated inverse method to calibrate thermal finite element models for numerical welding applications

Effect on properties of nickel alloy with the addition of iron and magnesium oxide by gas cladding method

State-of-the-art review on laser cladding process as an in-situ repair technique

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