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Simulation of Laser Heating of Aluminum and Model Validation via Two-Color Pyrometer and Shape Assessment
Fabrizia Caiazzo1, Vittorio Alfieri2
1Department of Industrial Engineering, University of Salerno, 84084 Fisciano, Italy. f.caiazzo@unisa.it.
Materials (Basel, Switzerland)
|August 24, 2018
Summary
A new thermal model accurately predicts laser heating in aluminum welds, reducing trial-and-error and enabling real-time control for optimized processing conditions and improved manufacturing.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Laser Processing
Background:
- Laser-based manufacturing requires precise control over processing parameters to avoid material defects and ensure product quality.
- Traditional trial-and-error methods for optimizing laser welding conditions are time-consuming and costly.
- Accurate thermal modeling is crucial for non-destructive, real-time control of laser heating processes.
Purpose of the Study:
- To develop and validate a thermal model for laser heating in non-penetrative bead-on-plate welds of aluminum alloy 2024.
- To improve the reliability of laser heating simulations by incorporating temperature-dependent material properties and a super-Gaussian intensity profile.
- To provide a foundation for advanced modeling of laser-based additive manufacturing repair processes.
Main Methods:
- A thermal model was developed for laser heating of aluminum alloy 2024 using a super-Gaussian transverse optical intensity profile.
- Temperature-dependent material property laws were integrated into the model to enhance simulation accuracy.
- Model outputs (thermal evolution and fusion zone geometry) were validated against experimental data obtained using a two-color pyrometer and cross-section analysis.
Main Results:
- The developed thermal model accurately predicts the peak temperature of the parent metal with an average error of 3%.
- The model effectively predicts the depth of the fusion zone with an average error of 4%.
- Experimental validation confirmed the model's capability in simulating thermal history and fusion zone characteristics.
Conclusions:
- The proposed thermal model offers a reliable and accurate method for simulating laser heating in aluminum alloy welds.
- The model's high accuracy in predicting thermal evolution and fusion zone geometry supports its use in optimizing laser processing conditions.
- This work lays the groundwork for future development of models for laser-based additive manufacturing repair applications.
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