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<p>The temperature field and molten pool dynamics during transverse oscillation laser welding of 5A06 aluminum alloy were investigated through coupled numerical simulation and experimental analysis. The influence of laser power (P) on thermal distribution, weld geometry, and microstructure evolution was systematically examined. Results show that increasing P leads to a higher maximum molten pool temperature and deeper penetration, with a 23.6% temperature increase observed when P rises from 2000 to 2200 W. Transverse oscillation effectively broadens the melt pool, reduces temperature gradients, promotes lateral metal flow, and homogenizes energy distribution, resulting in refined grain structures. The weld morphology transitions from a “W”-shaped profile at low P to a bowl-shaped geometry at higher P, while excessive P causes defects such as undercut, spatter, and burn-through. Optimal weld quality, characterized by a flat and uniform surface, was achieved at P = 2100 W. This study provides quantitative insights into the thermal-fluid behavior of aluminum alloy welds and offers guidance for optimizing transverse oscillation laser welding parameters in aerospace and automotive applications.</p>

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Simulation study on the temperature field and molten pool dynamics during transverse oscillation laser welding of 5A06 aluminum alloy and process optimization

  • 期刊论文

  • 发表日期：

    2026年4月9日

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  • Yingjian Ma,
  • Chengwei Yuan,
  • Chengyu Li,
  • Mengxue Wang,
  • Shuai Gao

摘要

The temperature field and molten pool dynamics during transverse oscillation laser welding of 5A06 aluminum alloy were investigated through coupled numerical simulation and experimental analysis. The influence of laser power (P) on thermal distribution, weld geometry, and microstructure evolution was systematically examined. Results show that increasing P leads to a higher maximum molten pool temperature and deeper penetration, with a 23.6% temperature increase observed when P rises from 2000 to 2200 W. Transverse oscillation effectively broadens the melt pool, reduces temperature gradients, promotes lateral metal flow, and homogenizes energy distribution, resulting in refined grain structures. The weld morphology transitions from a “W”-shaped profile at low P to a bowl-shaped geometry at higher P, while excessive P causes defects such as undercut, spatter, and burn-through. Optimal weld quality, characterized by a flat and uniform surface, was achieved at P = 2100 W. This study provides quantitative insights into the thermal-fluid behavior of aluminum alloy welds and offers guidance for optimizing transverse oscillation laser welding parameters in aerospace and automotive applications.