Implementation of real-time multiple reflection and Fresnel absorption of laser beam in keyhole

Abstract

A computational analysis of laser keyhole welding is achieved. The main driving force to make the molten pool as a narrow and deep keyhole is the recoil pressure induced by evaporation of the material. Also, the multiple reflection effect on the keyhole wall plays an important role in making the keyhole deeper and raising its total energy absorption rate. Multiple reflection and Fresnel absorption are implemented simultaneously with the proposed ray tracing technique in a discrete grid cell system during the simulation for every single time step. In particular, the Fresnel absorption model is chosen as an energy transfer mechanism from laser beam to workpiece. With all the governing equations including continuity, momentum and energy equation, the VOF method is adopted to trace the free surface of the molten pool. Simulation results are compared with the experimental ones to verify its validity. A pulsed Nd : YAG laser was used for keyhole welding experiments on mild steel plates of 7 mm thickness. It was observed that the generated keyhole maintains its solidified shape without any closing phenomenon both in the experiments and in the simulations.