Numerical and experimental study of the variation of keyhole depth with an aluminum alloy (AA1050)
The keyhole depth is a key measurement characteristic in the laser welding of busbar to battery tabs in battery packs for electric vehicles (EV), as it directly affects the quality of the weld. In this work, experiments are carried out with controlled and adjusted laser power and feed rate parameter...
| Main Authors: | , , , , , , |
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| Format: | Article |
| Language: | English |
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Elsevier
2024-06-01
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| Series: | Journal of Advanced Joining Processes |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S266633092400013X |
| _version_ | 1797303944368619520 |
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| author | Akash Meena Andreas Andersson Lassila Dan Lonn Kent Salomonsson Wei Wang Chris Valentin Nielsen Mohamad Bayat |
| author_facet | Akash Meena Andreas Andersson Lassila Dan Lonn Kent Salomonsson Wei Wang Chris Valentin Nielsen Mohamad Bayat |
| author_sort | Akash Meena |
| collection | DOAJ |
| description | The keyhole depth is a key measurement characteristic in the laser welding of busbar to battery tabs in battery packs for electric vehicles (EV), as it directly affects the quality of the weld. In this work, experiments are carried out with controlled and adjusted laser power and feed rate parameters to investigate the influence on the keyhole width, keyhole depth and porosities. A 3D numerical model of laser keyhole welding of an aluminum alloy (A1050) has been developed to describe the porosity formation and the keyhole depth variation. A new integration model of the recoil pressure and the rate of evaporation model is implemented which is closer to the natural phenomena as compared to the conventional methods. Additionally, major physical forces are employed including plume formation, upward vapor pressure and multiple reflection in the keyhole. The results show that keyhole depth is lower at higher feed rate, while lower feed rates result in increased keyhole depth. This study reveals that low energy densities result in an unstable keyhole with high spattering, exacerbated by increased laser power. Mitigating incomplete fusion is achieved by elevating laser energy density. The findings emphasize the critical role of keyhole depth in optimizing laser welding processes for applications like busbar-to-battery tab welding. |
| first_indexed | 2024-03-07T23:59:56Z |
| format | Article |
| id | doaj.art-9a5e6991f0404188aca8486b8eae44a7 |
| institution | Directory Open Access Journal |
| issn | 2666-3309 |
| language | English |
| last_indexed | 2024-03-07T23:59:56Z |
| publishDate | 2024-06-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Advanced Joining Processes |
| spelling | doaj.art-9a5e6991f0404188aca8486b8eae44a72024-02-18T04:44:26ZengElsevierJournal of Advanced Joining Processes2666-33092024-06-019100196Numerical and experimental study of the variation of keyhole depth with an aluminum alloy (AA1050)Akash Meena0Andreas Andersson Lassila1Dan Lonn2Kent Salomonsson3Wei Wang4Chris Valentin Nielsen5Mohamad Bayat6Department of Civil and Mechanical Engineering, Technical University of Denmark, 2800 Kgs, Lyngby, Denmark; Corresponding author.University of Skövde, Box 408, SE-541 28, Skövde, SwedenUniversity of Skövde, Box 408, SE-541 28, Skövde, SwedenUniversity of Skövde, Box 408, SE-541 28, Skövde, SwedenUniversity of Skövde, Box 408, SE-541 28, Skövde, SwedenDepartment of Civil and Mechanical Engineering, Technical University of Denmark, 2800 Kgs, Lyngby, DenmarkDepartment of Civil and Mechanical Engineering, Technical University of Denmark, 2800 Kgs, Lyngby, DenmarkThe keyhole depth is a key measurement characteristic in the laser welding of busbar to battery tabs in battery packs for electric vehicles (EV), as it directly affects the quality of the weld. In this work, experiments are carried out with controlled and adjusted laser power and feed rate parameters to investigate the influence on the keyhole width, keyhole depth and porosities. A 3D numerical model of laser keyhole welding of an aluminum alloy (A1050) has been developed to describe the porosity formation and the keyhole depth variation. A new integration model of the recoil pressure and the rate of evaporation model is implemented which is closer to the natural phenomena as compared to the conventional methods. Additionally, major physical forces are employed including plume formation, upward vapor pressure and multiple reflection in the keyhole. The results show that keyhole depth is lower at higher feed rate, while lower feed rates result in increased keyhole depth. This study reveals that low energy densities result in an unstable keyhole with high spattering, exacerbated by increased laser power. Mitigating incomplete fusion is achieved by elevating laser energy density. The findings emphasize the critical role of keyhole depth in optimizing laser welding processes for applications like busbar-to-battery tab welding.http://www.sciencedirect.com/science/article/pii/S266633092400013XMultiphysics simulationLaser weldingIncident angleMelt poolKeyhole depth and width |
| spellingShingle | Akash Meena Andreas Andersson Lassila Dan Lonn Kent Salomonsson Wei Wang Chris Valentin Nielsen Mohamad Bayat Numerical and experimental study of the variation of keyhole depth with an aluminum alloy (AA1050) Journal of Advanced Joining Processes Multiphysics simulation Laser welding Incident angle Melt pool Keyhole depth and width |
| title | Numerical and experimental study of the variation of keyhole depth with an aluminum alloy (AA1050) |
| title_full | Numerical and experimental study of the variation of keyhole depth with an aluminum alloy (AA1050) |
| title_fullStr | Numerical and experimental study of the variation of keyhole depth with an aluminum alloy (AA1050) |
| title_full_unstemmed | Numerical and experimental study of the variation of keyhole depth with an aluminum alloy (AA1050) |
| title_short | Numerical and experimental study of the variation of keyhole depth with an aluminum alloy (AA1050) |
| title_sort | numerical and experimental study of the variation of keyhole depth with an aluminum alloy aa1050 |
| topic | Multiphysics simulation Laser welding Incident angle Melt pool Keyhole depth and width |
| url | http://www.sciencedirect.com/science/article/pii/S266633092400013X |
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