Numerical simulation of droplet shapes in laser-MIG hybrid welding

A three-dimensional finite element model based on minimum energy principle is developed to simulate the droplet transfer process in laser-MIG hybrid welding. The energy manifestations of all forces that determine droplet shapes are considered in this model, and the model has been used to predict dro...

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Bibliographic Details
Published in:Optics and laser technology 2017-02, Vol.88, p.1-10
Main Authors: Lei, Zhenglong, Ni, Longchang, Li, Bingwei, Zhang, Kezhao
Format: Article
Language:English
Subjects:
Additional mechanical force
Centroids
Computer simulation
Droplet shapes
Droplets
Finite element analysis
Finite element method
Flow stability
Flow velocity
Gas flow
Laser beam welding
Laser-MIG hybrid welding
Mathematical models
Numerical analysis
Numerical simulation
Offsets
Shielding
Shielding gas
Studies
Three dimensional models
Welding
Welding current
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Summary:A three-dimensional finite element model based on minimum energy principle is developed to simulate the droplet transfer process in laser-MIG hybrid welding. The energy manifestations of all forces that determine droplet shapes are considered in this model, and the model has been used to predict droplet shapes. Offset of droplet centroid and critical additional axial acceleration are adopted to characterize the stability of droplet transfer. The calculated droplet shapes and offset of droplet centroid agree well with experimental results. It is found that increasing laser power or decreasing welding current would destabilize droplet transfer. Additional mechanical forces contribute to stable droplet transfer, and the positive effects of increased shielding gas flow rate on the stability of welding processes are subsequently verified. [Display omitted] •A mathematical model for droplet transfer in hybrid welding was developed.•Droplet shapes were successfully predicted based on minimum energy principle.•Additional mechanical forces could stabilize droplet transfer.•Critical shielding gas flow rate was calculated.
ISSN:0030-3992
1879-2545
DOI:10.1016/j.optlastec.2016.08.011