TY - JOUR A1 - Bachmann, Marcel A1 - Avilov, Vjaceslav A1 - Gumenyuk, Andrey A1 - Rethmeier, Michael T1 - Numerical assessment and experimental verification of the influence of the Hartmann effect in laser beam welding processes by steady magnetic fields JF - International journal of thermal sciences N2 - Controlling the dynamics in the weld pool is a highly demanding challenge in deep-penetration laser beam welding with modern high power laser systems in the multi kilowatt range. An approach to insert braking forces in the melt which is successfully used in large-scaled industrial applications like casting is the so-called Hartmann effect due to externally applied magnetic fields. Therefore, this study deals with its adaptation to a laser beam welding process of much smaller geometric and time scale. In this paper, the contactless mitigation of fluid dynamic processes in the melt by steady magnetic fields was investigated by numerical simulation for partial penetration welding of aluminium. Three-dimensional heat transfer, fluid dynamics including phase transition and electromagnetic field partial differential equations were solved based on temperature-dependent material properties up to evaporation temperature for two different penetration depths of the laser beam. The Marangoni convection in the surface region of the weld pool and the natural convection due to the gravitational forces were identified as main driving forces in the weld pool. Furthermore, the latent heat of solide-liquid phase transition was taken into account and the solidification was modelled by the Carman-Kozeny equation for porous medium morphology. The results show that a characteristic change of the flow pattern in the melt can be achieved by the applied steady magnetic fields depending on the ratio of magnetic induced and viscous drag. Consequently, the weld bead geometry was significantly influenced by the developing Lorentz forces. Welding experiments with a 16 kW disc laser with an applied magnetic flux density of around 500 mT support the numerical results by showing a dissipating effect on the weld pool dynamics. KW - Electromagnetic weld pool control KW - Hartmann effect KW - Laser beam weliding KW - Lorentz force KW - Marangoni flow KW - Natural convection KW - Aluminium PY - 2016 DO - https://doi.org/10.1016/j.ijthermalsci.2015.10.030 SN - 1290-0729 VL - 101 SP - 24 EP - 34 PB - Elsevier CY - Paris AN - OPUS4-35034 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Heßmann, Jennifer A1 - Bachmann, Marcel A1 - Hilgenberg, Kai T1 - Numerical and experimental investigation of controlled weld pool displacement by electromagnetic forces for joining dissimilar materials JF - Metals Special Issue Dissimilar Material Welding and Joining N2 - In order to reduce CO2 emissions, an increasing interest in lightweight construction exists in the automotive industry, especially the multi-material-design approach. The main construction materials here are steels and aluminium alloys. Due to their different physical material properties and limited mutual solubility, these two materials cannot be joined thermally without difficulty. This paper presents a new joining approach for dissimilar materials. It uses electromagnetic displacement of a laser-generated melt pool to produce overlap joints between 1 mm steel (1.0330) and 2 mm aluminium alloy (EN AW 5754). Contactless induced Lorentz forces are generated by an alternating current (AC) magnet system. The controlled displacement of the aluminium alloy melt into the hole of the overlying steel sheet is investigated through numerical and experimental studies. The numerical results are compared with cross sections and thermocouple measurements. For the first time, it is possible to achieve a reproducible controlled melt pool displacement on thin sheets to produce overlap joints between dissimilar materials. KW - Displacement KW - Laser beam welding KW - Dissimilar materials KW - Joining technology KW - Electromagnetic field KW - Lorentz force KW - Numerical investigation PY - 2020 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-516640 DO - https://doi.org/10.3390/met10111447 VL - 10 IS - 11 SP - 1447 EP - 1462 PB - MDPI CY - Basel, Schweiz AN - OPUS4-51664 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -