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b Abington
Received 24 November 2003; received in revised form 23 February 2004; accepted 24 February 2004
Abstract
The main emphasis of this review is on thermal modelling and prediction of laser welding in metals. However as similar techniques
are employed to model conventional welding processes such as arc, resistance and friction, as well as related processes such as alloying,
cladding and surface hardening, part of this review is given over to the modelling of these processes where appropriate. The time frame
of the review is up to the year 2002.
? 2004 Elsevier Ltd. All rights reserved.
Keywords: Modelling; Simulation; Laser welding; Welding; Surface treatment; Literature review
1. Introduction
The source material for this review is taken from a Doctoral Thesis entitled Numerical Simulations of Thermal
Processes and Welding by one of the authors (A.P.M),
submitted to the University of Essex, UK, in January
2003. References are therefore included up to the year
2002. One principal outcome of this doctoral work is a
=exible thermal modelling code named TS4D 1 (Thermal Simulation in 4 Dimensions, there being 3 spatial
dimensions + time). It is the culmination of modelling expertise at Essex University over a period of more than a
decade by the team supervised by Professors Phiroze Kapadia and John Dowden. TS4D can handle multiple sources
in both surface and volume format, surface sinks, multiple
material workpieces, a variety of surface cooling mechanisms, and produces both steady state and time-dependent
predictions.
Although the main emphasis of this review is on prediction of laser welding in metals, similar techniques
are employed to model conventional welding processes
such as arc, resistance and friction, as well as alloying,
cladding and surface hardening. Indeed modellers in one
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respectively. However, a typical keyhole weld is usually accompanied by a distinct nail head appearance at the top.
A line source model (where the source extends throughout the entire thickness of the domain) can only lead to a
parallel-sided weld of inDnite extent (i.e. a 2-D solution)
while a point source leads to a weld of roughly hemispherical shape.
Steen et al. [14] combined the point and line source to
model more eKectively a keyhole weld. This idea enabled the
estimation of the power actually absorbed by the weld. The
position of the point source could be variedon or within
the metal. Here the line source represents absorption down
the keyhole and the point source represents the plasma radiation from the plume. It was suggested that the melt width
in the lower part of the weld is directly proportional to the
strength of the line source. As this model assumes an inDnitely thick specimen, it is inappropriate for thin workpieces.
2.6. Extensions of the point/line source models
Akhter et al. [15], extended the solution of Steen et al.
[14] by producing a point and line source model for a
medium of Dnite thickness using the method of images. A
number of point sources were combined with a line source,
the strength of which varied with depth. This enabled more
realistic-looking melt cross-sections. The model was applied
to laser lap-welding of thin sheets of zinc-coated steel. Since
absorption of the laser beam often exhibits a local maximum at the interface of the two sheets, an additional point
source was used at this boundary. However, they were still
unable to model accurately the wine glass appearance of
some welds.
Hamoudi and Ducharme [16] produced a steady-state
welding model based on the point and line source model
of Steen et al. [14] with which they studied a series of
experimental welds in steel under the in=uence of helium
shielding gas. By varying the point and line source strengths
they matched the melt cross-sections as closely as possible
to those of experiment, determining the absorbed power.
They showed that the strength of the line source increases
with processing speed, including a sharp rise when the weld
penetration ceases to be full. In some cases the point source
strength was very small, indicating the eNciency of helium
as a shielding gas.
Another point and line source model was that of Lankalapalli et al. [17]. The keyhole was represented by a Dnite line
source whose strength varies with depth. They showed that
the temperature on the bottom surface of the workpiece is a
consistent indicator of penetration depth.
Postaciouglu et al. [18] produced a solution for the temperature Deld outside the melt pool using a spheroidal coordinate system, approximating the molten region as a half
prolate spheroid.
Kaplan [19], accounting for the fact that the keyhole
is not straight but curved, integrated point sources of an
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Phanikumar et al. [40] studying the laser welding of dissimilar metals, attempted modelling the welding of copper
and nickel. A pressure-based FV technique was employed
which involves phase change (using the enthalpy-porosity
technique [41,42]), convection in the melt pool, melting and
mixing. The dissimilar metal properties were handled using
appropriate mixture theories.
3.3. Multipass welding
Reed and Bhadeshia [43] constructed a partly analytic
partly numerical model to describe the thermal cycles occurring in multipass welds by using a matrix approach where
each element of the discretised workpiece is associated with
one element of a multidimensional matrix.
Lindgren et al. [44] produced a computer code to simulate
multipass butt welding. Since adding Dller wire increases
the volume of the workpiece, each pass either needs a reconstruction of the grid where new elements are added, or
it requires quiet elements which is more time-consuming.
The authors discuss the relative merits of both inactive and
quiet approaches and produce results for both methods. Although both methods gave similar results they could not
be compared with experimental results due to a number of
problems. Pulsed laser welding allows very low heat input
to the metal resulting in low distortion and enabling welding of heat-sensitive parts. Due to very rapid heating and
cooling, a continuous melt pool is not a feature and the role
of convection in pulsed laser welding is therefore minimal.
Frewin and Scott [45] produced a time-dependent 3-D
model of heat =ow during pulsed Nd:YAG laser welding,
using the FE code ANSYS. 2 Convective =ow in the melt
pool was ignored. Making use of temperature-dependent
material properties and experimentally measured beam
cross-sections, their model calculated transient temperature
cross-sections along with the dimensions of the fusion and
heat aKected zones. They found that the fusion and heat
aKected zones generated by their code were extremely close
to those produced experimentally, provided they assumed
a Gaussian energy distribution, but varied signiDcantly if a
top-hat distribution was used instead.
3.4. Melt pool models/thermocapillary >ow
The existence of =uid =ow and convection and their effects were Drst discussed in the 1950s [46]. Convection can
be regarded as the single most important factor in=uencing
the geometry of the melt pool leading to a change in pool
shape, the aspect ratio and the production of surface ripples. Furthermore it can cause various defects such as variable penetration, porosity and lack of fusion. As convection
2
ANSYS is a commercial software package that solves for the combined eKects of multiple forces, accurately modelling combined behaviours
resulting from multiphysics interactions. The software also features advanced nonlinear material simulation.
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the melt pool and solved a set of diKerential equations involving the heat conduction equation, an equation describing
the incompressibility condition together with the Navier
Stokes equation (to describe the viscous motion of the
molten material). Neglecting phase change, the diKerential
equations were converted to their dimensionless form and
solved numerically with FE methods. Diagrams of streamlines, velocity contours and temperature and pressure contours are shown. The molten material produces a long thin
jet behind the keyhole resulting in high pressure at the rear
end of the melt pool. The authors of the paper suggest that it
is this pressure which is responsible for the phenomenon of
humping (opposite of undercut) during fast laser welding.
Gratzke et al. [64] investigated humping in arc and laser
welding. Their theoretical model calculated the processing
speed needed for humping to occur and rejected the in=uence
of Marangoni convection but instead applied Rayleighs theory of instability of a free liquid cylinder due to surface
tension.
Lambrakos et al. [65] calculated the time-dependent
temperature and =uid velocity Deld for deep penetration
welding. The deposition of the power from the beam is
represented by time-dependent boundary conditions on the
equations of momentum and energy transfer. The boundary conditions are speciDed at each time-step on a surface
which changes with time. The model includes the eKect of
the surface tension gradient on the surface of the =uid and
the eKect of the buoyancy force. The coupled equations
of energy, momentum transfer and continuity, combined
with the time-dependent boundary conditions representing
the keyhole and the moving boundaries of the workpiece,
are solved using a speciDc implementation of the SIMPLE
[28] algorithm. With this model they were able to gauge
the relative in=uences of the electromagnetic force, surface
tension and the buoyancy force on =uid convection in the
melt pool. Their results demonstrate that =uid convection
in the melt pool is in=uenced far more by the stirring action
due to the keyhole vapour/liquid interface than by surface
tension.
Kar and Mazumder [66] produced a mathematical model
of laser keyhole welding to predict the depth and diameter of the keyhole, the surface velocity, the temperature
distribution and the melt pool shape. They considered
the forces generated at the liquidvapour interface due
to the surface tension gradient and also the energy balance at the liquidvapour and solidliquid interfaces.
They concluded that before the keyhole forms, the velocity Deld is large in the radial and azimuthal directions but thereafter it changes to a radially and axially
dominant Deld.
Including =ow in the melt pool, Kroos et al. [67] calculated the collapse time of the keyhole when the laser power
is suddenly shut down during stationary welding. They
assumed that the recoil pressure from ablating particles balances the surface tension at the keyhole wall. The keyhole
collapse time then determines the minimum required
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The pressure gradient arising in the liquid region surrounding the keyhole results in =ow parallel to the axis of
the laser. Postaciouglu et al. [73] calculated this velocity
of =ow, as well as the volume =ow rate, in modelling the
bulging in the liquid region at the mouth of the keyhole.
An estimate of the elevation or depression of the surface of
the weld and the shape of the surface cross-section is also
discussed.
SchuTocker [74] produced a model of deep penetration
welding in which the shape of the keyhole was interpolated
from the calculated temperature distribution. The keyhole
is kept open by a balance between the vapour pressure inside it (estimated from the ClausiusClapeyron equation)
and the hydrostatic pressure tending to close it. Dowden et
al. [75] produced a simple time-dependent model which describes the vapour =ow parallel to the axis of the keyhole
for medium processing speeds and also the possible presence of shock waves at the end of the keyhole. The authors
concluded that as the translation speed is increased, the laser
coupling eNciency becomes progressively more dominated
by direct absorption at the keyhole walls.
Kar et al. [76] developed a 2-D axisymmetric model of
material damage caused by melting and vaporisation during pulsed laser welding by taking into account multiple
re=ections of the laser beam at the keyhole wall. Both
solidliquid and liquidvapour interfaces were modelled
by applying the Stefan condition at various positions on
the interface. The whole problem was formulated using
the energy conservation equation and solved numerically
by the RungeKutta method [69]. They concluded that as
the laser intensity increases, the depth and cylindricity of
the cavity increase, whereas the recast layer thickness decreases, with multiple re=ections exaggerating the eKects.
They also found that liquid =ow had little eKect on cavity
depth and recast layer thickness, and that the dependence of
the cavity depth on the gross laser intensity was nonlinear
when multiple re=ections are taken into account, but linear
otherwise.
Ducharme et al. [77] produced a steady-state FD code
to compute the temperature distribution in and around the
hot plasma during laser processing with argon assist gas.
The refractive index of the plasma along with the relevant
gas properties vary with temperature. Equations are derived
relating the curved paths of the light rays to the temperature
gradients in the plasma with the attenuation of the laser
light calculated along these paths. The authors showed that
variations in the electron density due to iron vapour in the
plume cause spatial variations in the refractive index, giving
rise to thermal defocusing of the incident laser light well
before the critical density is achieved.
Considering a laser beam of Gaussian distribution, Metzbower [78] calculated the size and temperature of both the
keyhole and melt pool taking into account evaporation and
assuming that a minimum laser power density is required to
generate a keyhole. To study the mechanism of heat transfer
inside the keyhole, Tix and Simon [79] studied the transport
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Solana and OcaUna [87] determined the full 3-D melt pool
and keyhole geometry by setting the appropriate energy and
pressure balances. The energy balance takes into account
heat conduction, ablation losses and evaporation eKects at
the open surfaces of the keyhole as well as Fresnel absorption and inverse Bremsstrahlung, the keyhole being kept
open as a result of the balance between the ablation pressure
and the surface tension pressure. A time-dependent model
of the behaviour of the front keyhole wall during high translation speed laser welding was constructed by Matsunawa
and Semak [88]. This model was developed assuming that
(i) only the front part of the keyhole wall is exposed to the
high-intensity laser beam, (ii) recoil pressure exceeds surface tension, and (iii) propagation of the keyhole wall is
due to melt expulsion similar to that of laser drilling. Their
work shows that the keyhole wall velocity component parallel to the translation velocity can be greater than, equal to,
or less than the beam translation speed, and when higher,
the formation of humps on the keyhole are observed.
Kapadia et al. [89] produced two stochastic models to
describe the keyhole. The Drst model includes instabilities
and considers the formation of a partially penetrating keyhole under the action of a cw laser. The energy absorption
in the material is simpliDed so that it occurs exclusively in
instability events with each event moving a Dxed quantity of
energy per unit time from the incident laser beam power at
the top of the keyhole. In the second model the laser power
was absorbed in the keyhole both continuously as well as at
speciDc instability events.
Fabbro and Chouf [90,91] produced a model which studied the keyhole geometry as a function of the main operating parameters such as the processing speed, laser incident
intensity and material being welded. The model is based
on a drilling speed (i.e. the speed with which the keyhole
deepens) which when combined with the processing speed,
causes the inclination of the front keyhole wall. A stationary analytic model and a dynamic numerical model (which
takes into account a ray-tracing technique) enables the complete keyhole geometry to be determined by taking into account multiple re=ections inside the keyhole along with a
description of the closure process of the rear keyhole wall.
Pastor et al. [92] discuss the development of models in
order to study the eKect of positive and negative defocusing
on keyhole shape and weld temperature distribution during
laser keyhole welding.
3.6. Reviews
A review of analytic formulations and numerical models relating to deep penetration welding has been given by
Kapadia and Dowden [93]. Dowden and Kapadia [94] presented a further review of analytic solutions of the laser keyhole welding process by point and line sources. Lindgren
reviewed the modelling of welding by Dnite-element methods. His review is split into three parts [9597]. A comprehensive treatment by Dowden of the mathematics of thermal
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transitions. It consists of a reduced set of Maxwells equations, the heat transfer equation, and a system of ODEs for
the volume fractions of the occurring phases.
5.3. Surface/heat treatment
Singh and Mazumdar [164] described a time-dependent
3-D heat =ow model to estimate thermal Delds associated
with various heat treatment processes (e.g. heating above
critical temperatures, air cooling, water quenching operations, etc.). An appropriate coordinate system was chosen
in order to carry out numerical calculations for a wide range
of geometries (e.g. slab, parallelepiped, cylinder).
Gu et al. [165] constructed a 3-D model to calculate the
transient temperature Deld and the phase transformation
depth obtained in a Dnite workpiece during laser surface
treatment, allowing for the temperature dependence of the
material properties and taking into account convective and
radiative heat losses. Experimental results for the laser
hardening of a zirconium alloy agreed well with results
from their model. Rana et al. [166] incorporated an FD
implicit splitting method [167] in a model to estimate the
time-dependent temperature distribution in a Dnite-sized
sample during laser heat treatment. The discretised equations were solved using the tri-diagonal matrix algorithm
(TDMA) [28]. The heat source was assumed to have a Gaussian distribution and the thermal diKusivity was assumed
constant. Yilbas [168], using an explicit scheme, produced a
3-D solution to predict the Drst and second law eNciencies
and the entropy generation number [169] during laser heat
treatment.
Crafer and Mackwood [170] presented a fast 2-D
steady-state analytic model (where the temperature is independent of the lateral coordinate) for the temperature
distribution during surface treatment carried out by a moving source. The laser beam intensity is represented as a
number of parallel contiguous strips extending across the
entire width of the specimen and constituting a rectangular
source. The model is applicable to cases where the lateral
size of the workpiece is the same as the breadth of the raster
scan. The model has the ability to build tailored source
distributions and produces very quick solutions. The same
authors have since extended the approach with a 3-D model
with no restrictions on the lateral size of the beam or on the
lateral size of the specimen 4 .
Mazumder [171] gives a comprehensive review of laser
heat treatment and Tosto [172] reviews analytic and numerical laser surface treatment models.
5.4. Electron beam processes
Electron beam welding (EBW) is a high energy density
fusion welding process similar in its eKect to laser keyhole
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109
Friction stir welding is another solid-state process. Conceived in 1991, a cylindrical shouldered tool with a proDled
probe is rotated and pushed into the two pieces of metal being joined. The friction created by the rotating tool softens,
but does not melt the workpieces. The softened material is
transferred from the leading edge to the trailing edge of the
tool which is then forged by the contact of the tool shoulder
and pin proDle. This has been heralded by some as the most
remarkable joining process invented in the 1990s.
Metals can also be welded without melting by a further
solid-phase welding technique known as cold pressure welding [176].
Benzsak et al. [177] and Fu and Duan [178] have constructed models of the friction welding process and Chao and
Qi [179] and Grong and Midling [180] produced a model
relating to friction stir welding.
5.6. Resistance welding
Resistance welding is a process in which the application
of pressure along with resistance heating of the workpieces
produces coalescence of metals at the interface between the
two parts to be joined. Spot, seam and butt welding can all
be carried out using this process. In all resistance welding
processes the metal is heated locally until molten and then
allowed to cool, resulting in a weld nugget. The electric
current is produced by electrodes made of copper, due to
its high thermal conductivity, which ensures that the heat
is generated in the workpieces rather than in the electrodes.
Resistance welding is commonly used in the automobile
industry for its high eNciency and excellent quality control.
The interested reader is referred to references [181188].
5.7. Surface alloying/cladding
Surface alloying with a laser is similar to laser surface
melting with the exception that another material is incorporated into the melt pool. Laser surface alloying, studied
by Chande and Mazumder [189], also has similarities with
surface cladding, which if performed with excess power,
can result in surface alloying. (In cladding operations, one
material in liquid form is placed on top of another to form a
sound interfacial bond without diluting the cladding metal
with substrate material). Surface alloying and cladding
when performed by a laser, require minimal post-process
re-machining of the surface.
5.8. Microstructure models
The following publications relate to microstructure models [190198].
5.9. Residual stresses and deformations in welds
Thermal stress arises from restrained thermal expansion.
When welding, very large temperatures are produced in and
around the molten region which reduce quickly with
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References
Anthony and Cline [219] studied surface rippling induced by surface tension gradients during laser surface
melting and alloying and concluded that if the laser beam
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not have suNcient time to form ripples. Wang et al. [220]
produced a 2-D FE model to consider quenching problems involving non-isothermal phase changes, allowing for
temperature-dependent material properties. They applied
their model to the quenching of steel cylinders and an aluminium connector. Lind et al. [221,222] calculated the heat
transfer during cross-=ow quenching of a cylinder.
Garwood et al. [223] used a =uid dynamical computer
code to predict the =uid =ow distribution in an agitated
quench tank during heat treatment of superalloy forgings.
Olafsson et al. [224] used the thermodynamical computer
program ThermoCalc to predict thermal resistivities in heat
treated alloys. With the use of Matthiessens rule [225], they
determined the solubility of elements in commercial alloys
from which the resistivity was predicted.
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FE codes in 1, 2 or 3 dimensions from a symbolic speciDcation of the mathematical problem which enables the user
to model phase change, =uid =ow and heat transfer in material processes. The authors have used their toolbox to create
A.P. Mackwood, R.C. Crafer / Optics & Laser Technology 37 (2005) 99 115
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