Study of dimensionless quantities to analyse front and rear wall of keyhole formed during laser beam welding

Abstract

Fluid flow mechanisms present in Keyhole (KH) during Laser Beam Welding (LBW) process influence the associated heat and mass transfer. In an attempt to describe these complexities for eventual optimization of LBW parameters, a dimensionless analysis using Mach (Ma), Raleigh (Ra), Reynolds (Re) and Marangoni (Mg) numbers have been carried out. This analysis describes hydrodynamics of melt and vapour phase appearing in the front and rear wall of KH. The non-dimensional hydrodynamic quantities describe the mechanism behind flow pattern present in melt-vapour in terms of ratio of convection–conduction heat transfer occurring within KH. The analysis shows that the higher Marangoni number indicates stronger Marangoni convection in the KH causing relatively higher capillary flow in the melt pool. The laminar-turbulent flow of melt-vapour in KH medium is described in terms of ratio of Reynolds and Mach numbers (Re/Ma). The pressure distribution in the KH accounts for the melt-vapour ejection rate. A relationship between depth and radius of KH has been obtained as a function of delivered laser power.