Numerical Analysis of Thermal and Flow Behaviors with Weld Microstructures During Laser Welding with Filler Wire for 2195 Al-Li Alloys
This study investigates the effects of heat transfer and molten pool flow behavior on the final structure of laser filler wire welds, aiming to improve weld quality. Laser filler wire welding experiments and numerical simulations were performed on 2195 Al-Li alloy workpieces with varying welding par...
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| Format: | Article |
| Language: | English |
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MDPI AG
2025-03-01
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| Series: | Metals |
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| Online Access: | https://www.mdpi.com/2075-4701/15/4/348 |
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| author | Dejun Liu Qihang Xv Gan Tian Ling Zhao Xinzhi Yang Maochuan Li |
| author_facet | Dejun Liu Qihang Xv Gan Tian Ling Zhao Xinzhi Yang Maochuan Li |
| author_sort | Dejun Liu |
| collection | DOAJ |
| description | This study investigates the effects of heat transfer and molten pool flow behavior on the final structure of laser filler wire welds, aiming to improve weld quality. Laser filler wire welding experiments and numerical simulations were performed on 2195 Al-Li alloy workpieces with varying welding parameters. Numerical simulation of the heat transfer and flow in the molten pool was carried out using the CFD method, and the moving filler wire was introduced from the computational boundary by secondary development. Simulation results indicated that reducing welding speed and increasing wire feeding rate enhanced the cooling rate of the weld. Additionally, energy absorbed by the filler wire contributed between 6% and 16% of the total energy input during the liquid bridge transition. Comparing experimental and simulation data revealed that the cooling rate significantly affected the weld’s micro-structure and hardness. Notably, the formation of the equiaxed grain zone (EQZ) was crucial for weld performance. Excessive cooling rates hindered EQZ formation, reducing flow in this critical region. These findings offer valuable insights for optimizing welding parameters to enhance weld quality and performance. |
| format | Article |
| id | doaj-art-951ad7e73db043e4b7e94be9d2952a4d |
| institution | DOAJ |
| issn | 2075-4701 |
| language | English |
| publishDate | 2025-03-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj-art-951ad7e73db043e4b7e94be9d2952a4d2025-08-20T03:13:58ZengMDPI AGMetals2075-47012025-03-0115434810.3390/met15040348Numerical Analysis of Thermal and Flow Behaviors with Weld Microstructures During Laser Welding with Filler Wire for 2195 Al-Li AlloysDejun Liu0Qihang Xv1Gan Tian2Ling Zhao3Xinzhi Yang4Maochuan Li5College of Missile Engineering, Rocket Force University of Engineering, Xi’an 710025, ChinaCollege of Chemistry and Materials Science, Jinan University, Guangzhou 510632, ChinaCollege of Missile Engineering, Rocket Force University of Engineering, Xi’an 710025, ChinaCollege of Missile Engineering, Rocket Force University of Engineering, Xi’an 710025, ChinaCollege of Missile Engineering, Rocket Force University of Engineering, Xi’an 710025, ChinaCollege of Missile Engineering, Rocket Force University of Engineering, Xi’an 710025, ChinaThis study investigates the effects of heat transfer and molten pool flow behavior on the final structure of laser filler wire welds, aiming to improve weld quality. Laser filler wire welding experiments and numerical simulations were performed on 2195 Al-Li alloy workpieces with varying welding parameters. Numerical simulation of the heat transfer and flow in the molten pool was carried out using the CFD method, and the moving filler wire was introduced from the computational boundary by secondary development. Simulation results indicated that reducing welding speed and increasing wire feeding rate enhanced the cooling rate of the weld. Additionally, energy absorbed by the filler wire contributed between 6% and 16% of the total energy input during the liquid bridge transition. Comparing experimental and simulation data revealed that the cooling rate significantly affected the weld’s micro-structure and hardness. Notably, the formation of the equiaxed grain zone (EQZ) was crucial for weld performance. Excessive cooling rates hindered EQZ formation, reducing flow in this critical region. These findings offer valuable insights for optimizing welding parameters to enhance weld quality and performance.https://www.mdpi.com/2075-4701/15/4/348laser weldingAl-Li alloysfiller wirewelding wireEQZweld pool |
| spellingShingle | Dejun Liu Qihang Xv Gan Tian Ling Zhao Xinzhi Yang Maochuan Li Numerical Analysis of Thermal and Flow Behaviors with Weld Microstructures During Laser Welding with Filler Wire for 2195 Al-Li Alloys Metals laser welding Al-Li alloys filler wire welding wire EQZ weld pool |
| title | Numerical Analysis of Thermal and Flow Behaviors with Weld Microstructures During Laser Welding with Filler Wire for 2195 Al-Li Alloys |
| title_full | Numerical Analysis of Thermal and Flow Behaviors with Weld Microstructures During Laser Welding with Filler Wire for 2195 Al-Li Alloys |
| title_fullStr | Numerical Analysis of Thermal and Flow Behaviors with Weld Microstructures During Laser Welding with Filler Wire for 2195 Al-Li Alloys |
| title_full_unstemmed | Numerical Analysis of Thermal and Flow Behaviors with Weld Microstructures During Laser Welding with Filler Wire for 2195 Al-Li Alloys |
| title_short | Numerical Analysis of Thermal and Flow Behaviors with Weld Microstructures During Laser Welding with Filler Wire for 2195 Al-Li Alloys |
| title_sort | numerical analysis of thermal and flow behaviors with weld microstructures during laser welding with filler wire for 2195 al li alloys |
| topic | laser welding Al-Li alloys filler wire welding wire EQZ weld pool |
| url | https://www.mdpi.com/2075-4701/15/4/348 |
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