Three-dimensional modelling of heat transfer and fluid flow in laser full-penetration welding

Modelling results are presented concerning the laser full-penetration welding characteristics. The effects of welding speed, Marangoni convection and natural convection on melt flow and heat transfer are all included in the modelling, and thus a three-dimensional (3-D) approach is employed. Comparison of the present 3-D modelling results with corresponding two-dimensional ones shows that besides the welding speed, Marangoni convection also plays critical role in determining the temperature distribution in the workpiece and melt flow in the weld pool and cannot be ignored even for the full-penetration welding of a thin plate. A method is described concerning how to use the present 3-D modelling results to estimate the keyhole radius or predict the energy efficiency in the laser full-penetration welding.