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<p>Industrial laser welding requires rapid parameter optimization, but existing CFD models remain too computationally expensive for practical use. This work addresses this challenge through a calibrated multi-regime thermal source model that enables fast prediction of weld geometry while maintaining engineering accuracy. The model uniquely combines conduction and keyhole welding regimes within a single analytical framework, accounting for beam wobbling and plasma effects. Validated through bead-on-plate experiments on IN625 across industrial-relevant parameters, the approach reduces computational effort significantly compared to fluid dynamics simulations, making it suitable for industrial parameter screening and optimization.</p>

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A multi-regime thermal source model for laser welding process optimization

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年3月30日

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  • Paolo Ferro,
  • Riccardo Rossi,
  • Alessandra Varone,
  • Giuliano Angella,
  • Franco Bonollo,
  • Fabio Bergamini

摘要

Industrial laser welding requires rapid parameter optimization, but existing CFD models remain too computationally expensive for practical use. This work addresses this challenge through a calibrated multi-regime thermal source model that enables fast prediction of weld geometry while maintaining engineering accuracy. The model uniquely combines conduction and keyhole welding regimes within a single analytical framework, accounting for beam wobbling and plasma effects. Validated through bead-on-plate experiments on IN625 across industrial-relevant parameters, the approach reduces computational effort significantly compared to fluid dynamics simulations, making it suitable for industrial parameter screening and optimization.