Numerical and experimental analysis of laser welding process parameters on weld bead geometry

A finite element model has been developed to simulate the laser beam welding (LBW) process, which enjoys the capabilities of ABAQUS in transient thermal analysis. The substance used in this research was AISI 304 which thermal and mechanical properties are introduced to the model as temperature dependent. At first, a non-linear three-dimensional transient thermal model is developed, which calculates the temperature distribution in the local weld area and predicts the keyhole and weld bead size and shape. After the thermal analysis, the FE model is verified through the experimental work. After validation of the model, the effect of laser welding parameters on thermal distribution has been studied. Also, temperature variation on the weld line and on some points of distinct distances from the weld line during the heating and cooling procedure of the laser welding process has been examined. Results indicate that the major laser welding parameters affecting the weld bead geometry are laser power and velocity which have direct and reverse effect on the weld bead geometry, respectively. Also, among the material properties, conductivity is the dominant parameter, affecting the result of simulation.