Computational modeling of laser welding for aluminum–copper joints using a circular strategy
Dissimilar metal welding poses a significant challenge for researchers in the welding and materials science communities due to the different properties of the metals involved. In this study, we present a novel approach for determining the optimal processing parameters for continuous laser welding (C...
| Main Authors: | , , , |
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| Format: | Article |
| Language: | English |
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Elsevier
2023-07-01
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| Series: | Journal of Materials Research and Technology |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785423013698 |
| _version_ | 1797745232750575616 |
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| author | M. Mohsin Raza Yu-Lung Lo Hua-Bin Lee Chang Yu-Tsung |
| author_facet | M. Mohsin Raza Yu-Lung Lo Hua-Bin Lee Chang Yu-Tsung |
| author_sort | M. Mohsin Raza |
| collection | DOAJ |
| description | Dissimilar metal welding poses a significant challenge for researchers in the welding and materials science communities due to the different properties of the metals involved. In this study, we present a novel approach for determining the optimal processing parameters for continuous laser welding (CLW) of dissimilar metals, specifically aluminum and copper, using a circular strategy. The approach utilizes computational fluid dynamics (CFD) simulations to model the welding process and predict joint quality. We validated a CFD-based numerical model for predicting the melt-pool shape across a range of laser power and circular welding speed values. Additionally, we developed artificial neural network (ANN) models that can predict melt pool interface width, penetration depth, and copper concentration for any combination of processing conditions. Using surrogate modeling, we identified the optimal values of laser power and welding speed that result in the highest quality joint. Our results showed that the optimal processing conditions were a laser power of 2950W and a circular speed of 55 mm/s, which resulted in a high-quality Al–Cu joint with maximum shear strength of 2200 N. Microstructural analysis and tensile-shear strength testing confirmed that the optimal conditions resulted in a low degree of intermixing and the absence of large intermetallic compounds (IMCs) in the weld seam. Overall, study offers a valuable contribution to the welding and materials science communities by presenting a novel approach to address a common challenge in dissimilar metal welding. Our approach can be applied to other types of dissimilar metal welding and may inform the development of new welding techniques in the future. |
| first_indexed | 2024-03-12T15:21:24Z |
| format | Article |
| id | doaj.art-ffdfe56ce2d24fe6bb1a1d7ecc4c1609 |
| institution | Directory Open Access Journal |
| issn | 2238-7854 |
| language | English |
| last_indexed | 2024-03-12T15:21:24Z |
| publishDate | 2023-07-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj.art-ffdfe56ce2d24fe6bb1a1d7ecc4c16092023-08-11T05:33:37ZengElsevierJournal of Materials Research and Technology2238-78542023-07-012533503364Computational modeling of laser welding for aluminum–copper joints using a circular strategyM. Mohsin Raza0Yu-Lung Lo1Hua-Bin Lee2Chang Yu-Tsung3National Cheng Kung University, Department of Mechanical Engineering, Tainan, TaiwanNational Cheng Kung University, Department of Mechanical Engineering, Tainan, Taiwan; Corresponding author.Yulon Motors Co., Ltd, TaiwanYulon Motors Co., Ltd, TaiwanDissimilar metal welding poses a significant challenge for researchers in the welding and materials science communities due to the different properties of the metals involved. In this study, we present a novel approach for determining the optimal processing parameters for continuous laser welding (CLW) of dissimilar metals, specifically aluminum and copper, using a circular strategy. The approach utilizes computational fluid dynamics (CFD) simulations to model the welding process and predict joint quality. We validated a CFD-based numerical model for predicting the melt-pool shape across a range of laser power and circular welding speed values. Additionally, we developed artificial neural network (ANN) models that can predict melt pool interface width, penetration depth, and copper concentration for any combination of processing conditions. Using surrogate modeling, we identified the optimal values of laser power and welding speed that result in the highest quality joint. Our results showed that the optimal processing conditions were a laser power of 2950W and a circular speed of 55 mm/s, which resulted in a high-quality Al–Cu joint with maximum shear strength of 2200 N. Microstructural analysis and tensile-shear strength testing confirmed that the optimal conditions resulted in a low degree of intermixing and the absence of large intermetallic compounds (IMCs) in the weld seam. Overall, study offers a valuable contribution to the welding and materials science communities by presenting a novel approach to address a common challenge in dissimilar metal welding. Our approach can be applied to other types of dissimilar metal welding and may inform the development of new welding techniques in the future.http://www.sciencedirect.com/science/article/pii/S2238785423013698Continuous laser welding (CLW)Computational fluid dynamics (CFD)Artificial neural network (ANN)Parameter optimizationIntermetallic compound (IMC) |
| spellingShingle | M. Mohsin Raza Yu-Lung Lo Hua-Bin Lee Chang Yu-Tsung Computational modeling of laser welding for aluminum–copper joints using a circular strategy Journal of Materials Research and Technology Continuous laser welding (CLW) Computational fluid dynamics (CFD) Artificial neural network (ANN) Parameter optimization Intermetallic compound (IMC) |
| title | Computational modeling of laser welding for aluminum–copper joints using a circular strategy |
| title_full | Computational modeling of laser welding for aluminum–copper joints using a circular strategy |
| title_fullStr | Computational modeling of laser welding for aluminum–copper joints using a circular strategy |
| title_full_unstemmed | Computational modeling of laser welding for aluminum–copper joints using a circular strategy |
| title_short | Computational modeling of laser welding for aluminum–copper joints using a circular strategy |
| title_sort | computational modeling of laser welding for aluminum copper joints using a circular strategy |
| topic | Continuous laser welding (CLW) Computational fluid dynamics (CFD) Artificial neural network (ANN) Parameter optimization Intermetallic compound (IMC) |
| url | http://www.sciencedirect.com/science/article/pii/S2238785423013698 |
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