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<p>Aluminum alloys, known for high electrical/thermal conductivity, corrosion resistance, cost-effectiveness, and lightweight properties, are extensively used in aerospace and new energy vehicles. Laser welding offers advantages for joining battery tabs/busbars but faces challenges like thermal expansion and conductivity in thin-plate aluminum alloys, requiring precise parameter optimization. Experimental optimization is limited by cost and mechanistic complexity, making mathematical modeling preferable. Previous studies focused on thicker plates and homogeneous alloys, neglecting molten pool-based parameter optimization. This study selected 1050Al (tabs) and 6061Al (busbars), establishing a nonlinear transient heat conduction model via ANSYS Fluent. A Gaussian rotating surface volume heat source simulated temperature fields and molten pool characteristics during laser deep penetration welding. Simulations tested laser powers (550–950 W) at 55&#xa0;mm/s and welding speeds (25–65&#xa0;mm/s) at 700 W, with the results validated experimentally. Results revealed a steep temperature gradient near the heat source, with heat-affected zones above 400&#xa0;K. Simulated and actual molten pools showed strong alignment: fusion width deviation 4.93%, depth deviation 4.88%. Depth-to-width ratio optimization identified 0.32 (<i>P</i> = 650 W, <i>v</i> = 55&#xa0;mm/s) as optimal, yielding superior mechanical properties. Corresponding welds exhibited clear ripple patterns, straight base material-weld boundaries, and 765.41 N shear strength. Fracture surfaces displayed tear-shaped edges indicative of pure shear. EDS analysis showed weld regions comprising 98.92% α-Al (0.64% Mg, 0.42% Si), while near-weld areas contained 97.94% α-Al with 1.41% Mg and 0.65% Si (including Mg<sub>2</sub>Si), mitigating corrosion resistance loss. The numerical simulation method presented in this study can be used to guide the selection of process parameters in the actual welding of thin-plate dissimilar aluminum alloys, thereby improving welding efficiency and quality.</p>

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Numerical simulation of temperature field and melting pool characteristics in laser deep penetration welding of thin sheet heterogeneous aluminum alloys

  • 期刊论文

  • 发表日期：

    2025年6月3日

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  • Yan Wu,
  • Jiaqing Ye,
  • Guofeng Sun,
  • Wenjun Lv,
  • Jiawei Gu,
  • Xuhui Liu

摘要

Aluminum alloys, known for high electrical/thermal conductivity, corrosion resistance, cost-effectiveness, and lightweight properties, are extensively used in aerospace and new energy vehicles. Laser welding offers advantages for joining battery tabs/busbars but faces challenges like thermal expansion and conductivity in thin-plate aluminum alloys, requiring precise parameter optimization. Experimental optimization is limited by cost and mechanistic complexity, making mathematical modeling preferable. Previous studies focused on thicker plates and homogeneous alloys, neglecting molten pool-based parameter optimization. This study selected 1050Al (tabs) and 6061Al (busbars), establishing a nonlinear transient heat conduction model via ANSYS Fluent. A Gaussian rotating surface volume heat source simulated temperature fields and molten pool characteristics during laser deep penetration welding. Simulations tested laser powers (550–950 W) at 55 mm/s and welding speeds (25–65 mm/s) at 700 W, with the results validated experimentally. Results revealed a steep temperature gradient near the heat source, with heat-affected zones above 400 K. Simulated and actual molten pools showed strong alignment: fusion width deviation 4.93%, depth deviation 4.88%. Depth-to-width ratio optimization identified 0.32 (P = 650 W, v = 55 mm/s) as optimal, yielding superior mechanical properties. Corresponding welds exhibited clear ripple patterns, straight base material-weld boundaries, and 765.41 N shear strength. Fracture surfaces displayed tear-shaped edges indicative of pure shear. EDS analysis showed weld regions comprising 98.92% α-Al (0.64% Mg, 0.42% Si), while near-weld areas contained 97.94% α-Al with 1.41% Mg and 0.65% Si (including Mg2Si), mitigating corrosion resistance loss. The numerical simulation method presented in this study can be used to guide the selection of process parameters in the actual welding of thin-plate dissimilar aluminum alloys, thereby improving welding efficiency and quality.