Optimization of static and dynamic beam shapes for laser beam welding by means of numerical process simulations

Abstract

Although laser beam welding has established a prominent position in the industry and delivered commendable solutions for specific applications, the technology faces increasingly intricate challenges as welding process requirements evolve. The criticality of common weld defects, such as porosity, lack of fusion, irregular penetration depth, cracks, undercut, or spatter, is amplified by the growing complexity of weld parameters. Recent advancements in static and dynamic beam shaping, including homogenization, beam splitting, beam forming, beam oscillation, beam modulation, and adaptive beam shaping, have provided significant opportunities to control heat input and address these challenges. In-depth numerical simulations enable the modeling of a broad spectrum of multiphysical phenomena, including beam propagation, multiple reflections, phase changes, grain growth, and the dynamics of vapor and melt flows, facilitating comprehensive process understanding. Consequently, these simulations serve as valuable tools for optimizing beam shaping and weld parameters.