Modeling of Yb:YAG Laser Beam Caustics and Thermal Phenomena in Laser-Arc Hybrid Welding Process with Phase Transformations in the Solid State

This paper focuses on the mathematical and numerical modeling of the electric arc + laser beam welding (HLAW) process using an innovative model of the Yb:YAG laser heat source. Laser energy distribution is measured experimentally using a UFF100 analyzer. The results of experimental research, including the beam profile and energetic characteristics of an electric arc, are used in the model. The laser beam description is based on geostatistical kriging interpolation, whereas the electric arc is modeled using Goldak's distribution. Hybrid heat source models are used in numerical algorithms to analyze physical phenomena occurring in the laser-arc hybrid welding process. Thermal phenomena with fluid flow in the fusion zone (FZ) are described by continuum conservation equations. The kinetics of phase transformations in the solid state are determined using Johnson-Mehl-Avrami (JMA) and Koistinen-Marburger (KM) equations. A continuous cooling transformation (CCT) diagram is determined using interpolation functions and experimental research. An experimental dilatometric analysis for the chosen cooling rates is performed to define the start and final temperatures as well as the start and final times of phase transformations. Computer simulations of butt-welding of S355 steel are executed to describe temperature and melted material velocity profiles. The predicted FZ and heat-affected zone (HAZ) are compared to cross-sections of hybrid welded joints, performed using different laser beam focusing. The obtained results confirm the significant influence of the power distribution of the heat source and the laser beam focusing point on the temperature distribution and the characteristic zones of the joint.