TY - JOUR
T1 - Revealing the effects of laser beam shaping on melt pool behaviour in conduction-mode laser melting
AU - Ebrahimi, Amin
AU - Sattari, Mohammad
AU - Babu, Aravind
AU - Sood, Arjun
AU - Römer, Gert Willem R.B.E.
AU - Hermans, Marcel J.M.
N1 - Publisher Copyright:
© 2023 The Author(s)
PY - 2023/11/1
Y1 - 2023/11/1
N2 - Laser beam shaping offers remarkable possibilities to control and optimise process stability and tailor material properties and structure in laser-based welding and additive manufacturing. However, little is known about the influence of laser beam shaping on the complex melt-pool behaviour, solidified melt-track bead profile and microstructural grain morphology in laser material processing. A simulation-based approach is utilised in the present work to study the effects of laser beam intensity profile and angle of incidence on the melt-pool behaviour in conduction-mode laser melting of stainless steel 316L plates. The present high-fidelity physics-based computational model accounts for crucial physical phenomena in laser material processing such as complex laser–matter interaction, solidification and melting, heat and fluid flow dynamics, and free-surface oscillations. Experiments were carried out using different laser beam shapes and the validity of the numerical predictions is demonstrated. The results indicate that for identical processing parameters, reshaping the laser beam leads to notable changes in the thermal and fluid flow fields in the melt pool, affecting the melt-track bead profile and solidification microstructure. The columnar-to-equiaxed transition is discussed for different laser-intensity profiles.
AB - Laser beam shaping offers remarkable possibilities to control and optimise process stability and tailor material properties and structure in laser-based welding and additive manufacturing. However, little is known about the influence of laser beam shaping on the complex melt-pool behaviour, solidified melt-track bead profile and microstructural grain morphology in laser material processing. A simulation-based approach is utilised in the present work to study the effects of laser beam intensity profile and angle of incidence on the melt-pool behaviour in conduction-mode laser melting of stainless steel 316L plates. The present high-fidelity physics-based computational model accounts for crucial physical phenomena in laser material processing such as complex laser–matter interaction, solidification and melting, heat and fluid flow dynamics, and free-surface oscillations. Experiments were carried out using different laser beam shapes and the validity of the numerical predictions is demonstrated. The results indicate that for identical processing parameters, reshaping the laser beam leads to notable changes in the thermal and fluid flow fields in the melt pool, affecting the melt-track bead profile and solidification microstructure. The columnar-to-equiaxed transition is discussed for different laser-intensity profiles.
KW - Bead profile
KW - Fusion welding and additive manufacturing
KW - High-fidelity numerical simulation
KW - Laser beam shaping
KW - Melt pool behaviour
KW - Microstructural grain morphology
UR - http://www.scopus.com/inward/record.url?scp=85176268814&partnerID=8YFLogxK
U2 - 10.1016/j.jmrt.2023.11.046
DO - 10.1016/j.jmrt.2023.11.046
M3 - Article
AN - SCOPUS:85176268814
SN - 2238-7854
VL - 27
SP - 3955
EP - 3967
JO - Journal of Materials Research and Technology
JF - Journal of Materials Research and Technology
ER -