A 3D transient model of keyhole and melt pool dynamics in laser beam welding applied to the joining of zinc coated sheets

In order to get a deeper understanding of laser beam welding, a process model was developed at the Chair of Manufacturing Technology. It is based on the continuity equation, the equation of heat conduction and the Navier–Stokes equation. The model includes effects of Fresnel absorption, vapor pressure, surface tension, melting and evaporation enthalpy and energy loss due to evaporating material. This paper presents the results of a three-dimensional, transient finite volume simulation of a laser beam deep penetration welding process based on this model. The simulations show periodic keyhole oscillations and the complex fluid dynamics of the melt pool. A comparison of the evaporation rates calculated from the simulations and the experimentally observed process emissions shows good correlation. Furthermore, the simulations show pore formation at higher feed rates, the influence of a gap on the welding process and give an explanation for the welding behavior of zinc coated steel sheets.