Reconstruction of the time-averaged keyhole geometry in laser beam welding with electromagnetic support

  • In laser beam welding (LBW), the time-averaged keyhole shape provides statistical insights into the process compared to its transient geometry, offering a deeper understanding of the overall keyhole behaviour. However, capturing the time-averaged keyhole shape through experimental methods remains challenging. In this paper, a reconstruction algorithm for the time-averaged keyhole is developed and integrated into a three-dimensional transient multi-physical coupled numerical model. The algorithm can accurately capture the key characteristics of the keyhole, including its diameter and centroid. In addition, it can also successfully reproduce the experimentally observed phenomena of keyhole tailing. The overall shape of the keyhole appears smooth, without exhibiting obvious instability features. Furthermore, the time-averaged keyhole shape is compared under different magnetic flux densities when an external oscillating magnetic field is applied. The results indicate that the applicationIn laser beam welding (LBW), the time-averaged keyhole shape provides statistical insights into the process compared to its transient geometry, offering a deeper understanding of the overall keyhole behaviour. However, capturing the time-averaged keyhole shape through experimental methods remains challenging. In this paper, a reconstruction algorithm for the time-averaged keyhole is developed and integrated into a three-dimensional transient multi-physical coupled numerical model. The algorithm can accurately capture the key characteristics of the keyhole, including its diameter and centroid. In addition, it can also successfully reproduce the experimentally observed phenomena of keyhole tailing. The overall shape of the keyhole appears smooth, without exhibiting obvious instability features. Furthermore, the time-averaged keyhole shape is compared under different magnetic flux densities when an external oscillating magnetic field is applied. The results indicate that the application of external magnetic fields does not fundamentally alter the overall keyhole shape. With increasing magnetic flux density, the trailing tail becomes progressively less pronounced and a noticeable increase in the curvature of the rear wall is observed. The standard deviation of the keyhole diameter can serve as an effective index for evaluating the keyhole instability. Keyhole stability in LBW of aluminium alloys is improved under the assistance of electromagnetic fields, and this stabilization is positively correlated with increasing magnetic flux density.zeige mehrzeige weniger

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Autor*innen:Marcel Bachmann
Koautor*innen:Fan Yang, Xiangmeng Meng, Stephen Nugraha Putra, Michael RethmeierORCiD
Dokumenttyp:Vortrag
Veröffentlichungsform:Präsentation
Sprache:Englisch
Jahr der Erstveröffentlichung:2025
Organisationseinheit der BAM:9 Komponentensicherheit
9 Komponentensicherheit / 9.3 Schweißtechnische Fertigungsverfahren
DDC-Klassifikation:Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Ingenieurwissenschaften und zugeordnete Tätigkeiten
Freie Schlagwörter:Electromagnetic weld pool support; Keyhole reconstruction; Keyhole stability; Laser beam welding; Porosity defects
Themenfelder/Aktivitätsfelder der BAM:Material
Material / Degradationsmechanismen
Veranstaltung:14th International Seminar Numerical Analysis of Weldability
Veranstaltungsort:Seggau, Austria
Beginndatum der Veranstaltung:21.09.2025
Enddatum der Veranstaltung:24.09.2025
Verfügbarkeit des Dokuments:Datei im Netzwerk der BAM verfügbar ("Closed Access")
Datum der Freischaltung:06.10.2025
Referierte Publikation:Nein
Eingeladener Vortrag (wissenschaftliche Konferenzen):Nein
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