Porosity Formation in Laser Welded Ti‐6Al‐4V Alloy: Modelling and Validation

An Integrated Modeling Approach for Predicting Process Maps of Residual Stress and Distortion in a Laser Weld: A Combined CFD–FE Methodology

“…A detailed description of the model adopted can be found in the previous work of Panwisawas et al [19] The thermal fluid dynamics calculation is computed based upon the evolution of the thermal field coupled with the Navier-Stokes equation for fluid flow. The flow calculation has included vaporization (recoil pressure), solid-liquid and liquid-vapor phase changes, surface tension, and thermal-capillary effects or Marangoni flow; moreover, an adaptive volumetric heat source model modified from literature [20] has been used to simulate the energy reflection inside the keyhole.…”

“…Using this CFD modeling framework, [19] a series of CFD models were performed (Table I), considering the heat source traveling through a thin plate (a typical bead-on-plate weld) with varying process parameter sets (welding speed and welding source power). The predicted thermal results were used to predict a representative weld pool size and shape for each of the welds.…”

“…To reduce the computational time and resource, one might use a simplified version, to provide a sensible timescale for obtaining the weld pool dimension with various processing inputs. Panwisawas et al [19] have proposed a keyhole model, which can be used to predict the melt pool geometry as a function of processing conditions, reflecting the melt flow behavior during the welding operation. Whilst the CFD modeling can predict complex fluid flow and interface phenomena, coupling of this model with a finite-element approach is required in order to achieve the detailed predictions about the mechanical behavior.…”