Numerical simulation of laser-generated ultrasound in non-metallic material by the finite element method

The use of a pulsed laser for the generation of the elastic waves in non-metallic materials in the thermoelastic regime is investigated by using finite element method (FEM), taking into account not only thermal diffusion and the finite spatial and temporal shape of the laser pulse, but also optical penetration and the temperature dependence of material properties. The optimum finite element model is established based on analysis of two important parameters, meshing size and time step, and the stability of solution. Temperature distributions and temperature gradient fields in non-metallic material for different time steps are obtained, this temperature field is equivalent to a bulk force source to generate ultrasonic wave. The laser-generated ultrasound waveforms at the epicenter and surface acoustic waveforms (SAWs) are obtained and the influence of optical penetration into the material on the temperature field and the ultrasound waveforms are analyzed. The numerical results indicate that the heat penetration into non-metallic material is caused mainly by the optical penetration, and the ultrasound waveforms, especially the shape of the precursor, are strongly dependent on the optical penetration depth into non-metallic material.     

Modeling of laser transmission contour welding process using FEA and DoE

In this research, a systematic investigation on laser transmission contour welding process is carried out using finite element analysis (FEA) and design of experiments (DoE) techniques. First of all, a three-dimensional thermal model is developed to simulate the laser transmission contour welding process with a moving heat source. The commercial finite element code ANSYS^® multi-physics is used to obtain the numerical results by implementing a volumetric Gaussian heat source, and combined convection–radiation boundary conditions. Design of experiments together with regression analysis is then employed to plan the experiments and to develop mathematical models based on simulation results. Four key process parameters, namely power, welding speed, beam diameter, and carbon black content in absorbing polymer, are considered as independent variables, while maximum temperature at weld interface, weld width, and weld depths in transparent and absorbing polymers are considered as dependent variables. Sensitivity analysis is performed to determine how different values of an independent variable affect a particular dependent variable.     

Effect of carbon black on temperature field and weld profile during laser transmission welding of polymers: A FEM study

The influence of the carbon black on temperature distribution and weld profile, during laser transmission welding of polymers, is investigated in the present research work. A transient numerical model, based on conduction mode heat transfer, is developed to analyze the process. The heat input to the model is considered to be the volumetric Gaussian heat source. The computation of temperature field during welding is carried out for polycarbonates having different proportion of carbon black in polymer matrix. The temperature dependent material properties of polycarbonate are taken into account for modeling. The finite element code ANSYS^® is employed to obtain the numerical results. The numerically computed results of weld pool dimensions are compared with the experimental results. The comparison shows a fair agreement between them, which gives confidence to use the developed model for intended investigation with acceptable accuracy. The results obtained have revealed that the carbon black has considerable influence on the temperature field distribution and the formation of the weld pool geometry.     

3D transient multiphase model for keyhole,vapor plume,and weld pool dynamics in laser welding including the ambient pressure effect

The physical process of deep penetration laser welding involves complex, self-consistent multiphase keyhole, metallic vapor plume, and weld pool dynamics. Currently, efforts are still needed to understand these multiphase dynamics. In this paper, a novel 3D transient multiphase model capable of describing a self-consistent keyhole, metallic vapor plume in the keyhole, and weld pool dynamics in deep penetration fiber laser welding is proposed. Major physical factors of the welding process, such as recoil pressure, surface tension, Marangoni shear stress, Fresnel absorptions mechanisms, heat transfer, and fluid flow in weld pool, keyhole free surface evolutions and solid–liquid–vapor three phase transformations are coupling considered. The effect of ambient pressure in laser welding is rigorously treated using an improved recoil pressure model. The predicated weld bead dimensions, transient keyhole instability, weld pool dynamics, and vapor plume dynamics are compared with experimental and literature results, and good agreements are obtained. The predicted results are investigated by not considering the effects of the ambient pressure. It is found that by not considering the effects of ambient pressure, the average keyhole wall temperature is underestimated about 500 K; besides, the average speed of metallic vapor will be significantly overestimated. The ambient pressure is an essential physical factor for a comprehensive understanding the dynamics of deep penetration laser welding.     

Optimization of hybrid laser – TIG welding of 316LN steel using response surface methodology (RSM)

In the present study, the hybrid laser – TIG welding parameters for welding of 316LN austenitic stainless steel have been investigated by combining a pulsed laser beam with a TIG welding heat source at the weld pool. Laser power, pulse frequency, pulse duration, TIG current were presumed as the welding process parameters whereas weld bead width, weld cross-sectional area and depth of penetration (DOP) were considered as the process responses. Central composite design was used to complete the design matrix and welding experiments were conducted based on the design matrix. Weld bead measurements were then carried out to generate the dataset. Multiple regression models correlating the process parameters with the responses have been developed. The accuracy of the models were found to be good. Then, the desirability approach optimization technique was employed for determining the optimum process parameters to obtain the desired weld bead profile. Validation experiments were then carried out from the determined optimum process parameters. There was good agreement between the predicted and measured values.     

A keyhole volumetric model for weld pool analysis in Nd:YAG pulsed laser welding

This study presents a new model for analyzing the temperature distribution and weld pool shape in Nd:YAG pulsed laser welding. In the proposed approach, a surface flux heat transfer model is applied in the low laser energy intensity region of the weld, while a keyhole heat transfer model based on a volumetric heat source is applied in the high laser energy intensity region of the weld. The correlation between the intensity of the laser input energy and the geometric parameters of the volumetric heat source is derived experimentally. A series of MARC finite element simulations based on the proposed single pulse model are performed to investigate the shape and size of the weld pool given different laser energy intensities. A good agreement is observed between the simulation results and the experimental results obtained under equivalent single pulse welding conditions. Thus, the basic validity of the proposed model is confirmed.     

Metal absorptivity in femtosecond pulsed laser ablation

In this paper, the effect of the absorptivity of metal on femtosecond pulsed laser ablation is investigated. The formulas for the absorptivity depending on target temperature are derived from Maxwell Equations and the Lambert-Beer’s law. Based on this, a new two-temperature model is proposed to describe the femtosecond pulsed laser ablation with metal. Then, using Au as an example, a finite difference method is employed to simulate the space-dependent and time-dependent absorptivity and the target temperature. The temperature evolution of our model is compared with the result obtained form the heat conduction model taking the absorptivity as constant. It is shown that the absorptivity plays an important role in the femtosecond pulsed laser ablation. The results of this paper are helpful in choosing the best technical parameters in femtosecond pulsed laser ablation.      

RIBLLⅡ与CSRe中束流控制系统的设计

介绍了兰州重离子加速器冷却存储环（HIRFL-CSR）的实验环CSRe以及次级束线RIBLLⅡ中束流控制系统的设计。该系统主要采用了Java,COM,Oracle,ARM,DSP,FPGA等技术实现了对磁铁电源的实时、同步控制,已达到对束流的控制。该系统已经运行于现场的束流调试中,并在RIBLLⅡ的束流调试中运行正常、性能稳定。     

等离子弧焊接熔池演变过程的模拟和验证

本文建立了描述等离子弧焊接熔池相变传热与流动的三维数理模型,考虑表面张力、电磁力和浮升力的作用,并针对等离子弧焊接特点,改进组合式体积热源模型,上部采用双椭球热源,下部采用圆锥体热源。重点分析了焊接熔池形状和温度场的演变过程,熔合线的模拟形状与实验焊缝吻合,较好地呈现了焊缝的凸起和熔池宽度,验证了数学模型和热源模型的正确性。本文还进一步开展了焊接功率和焊接速度的影响分析。研究结果表明,流动对焊缝形状的影响不容忽略,而表面张力在三个流动驱动力中占主导地位;焊接功率越大,焊接速度越小,越有利于焊件焊透,数值模拟得到优化的焊接功率和速度有益于实际焊接生产质量及效率。     

双面电弧焊接的传热模型

将等离子焊接(PAW)电弧和钨极氩弧焊(TIG)电弧串接,相对作用于工件的正反面形成双面电弧焊接(DSAW)系统,可以引导焊接电流沿工件厚度方向流过小孔,补偿等离子电弧穿透工件时消耗的能量,以有效地提高等离子弧的穿透能力.综合考虑影响双面电弧焊接正反面熔池几何形状的力学因素,建立了熔池表面变形的控制方程,以此为基础并采用帖体曲线坐标系建立了DSAW焊接传热的数学模型,分析了DSAW,PAW焊接传热的差异,从传热的角度解释了DSAW焊接熔深增加的原因.焊接工艺实验表明,计算结果与实测结果吻合良好. 关键词： 双面电弧焊接(DSAW) 传热模型 熔池表面变形模型     

Process Window for Nd:YAG Laser Welding of Super Duplex Stainless Steel

Super duplex stainless steel (SDSS), an advanced duplex stainless steel with higher alloying concentration, is employed widely in acidic atmospheres. In this study, we make an attempt to develop a process window for the pulsed mode Nd:YAG laser welding of SDSS, as reference maps, to identify the range of process parameters viz., laser power, welding speed, defocusing distance, and pulse frequency for obtaining a defect free full penetration welds. The eminence of the welds, based on the macrostructure, microstructure, and tensile strength, is reported. We obtain a complete penetration weld devoid of undercut, crating at the top and minimum heat affected zone (HAZ) with a overlapping factor of 80–90% and heat input at 100–200 J/mm. The experimental settings prevailing inside the preferred region of the process window exhibit a higher tensile strength as well.     

An investigation on capability of hybrid Nd:YAG laser-TIG welding technology for AA2198 Al-Li alloy

This paper surveys the capability of the hybrid laser-arc welding in comparison with lone laser welding for AA2198 aluminum alloy experimentally. In the present research, a continuous Nd:YAG laser with a maximum power of 2000 W and a 350 A electric arc were used as two combined welding heat sources. In addition to the lone laser welding experiments, two strategies were examined for hybrid welding; the first one was low laser power (100 W) accompanied by high arc energy, and the second one was high laser power (2000 W) with low arc energy. Welding speed and arc current varied in the experiments. The influence of heat input on weld pool geometry was surveyed. The macrosection, microhardness profile and microstructure of the welded joints were studied and compared. The results indicated that in lone laser welding, conduction mode occurred and keyhole was not formed even in low welding speeds and thus the penetration depth was so low. It was also found that the second approach (high laser power accompanied with low arc energy) is superior to the first one (low laser power accompanied with high arc energy) in hybrid laser-arc welding of Al2198, since lower heat input was needed for full penetration weld and as a result a smaller HAZ was created.     

短脉冲激光对硅基探测器的热作用模型选择

从傅里叶模型和非傅里叶模型的基本方程出发,通过有限差分方法对方程进行数值求解。分别分析了10,1．0,0．1,0．01 ns这4种脉宽的脉冲激光作用于硅材料时两种传热模型温度曲线的相对变化;讨论了热弛豫时间对非傅里叶模型数值结果的影响。结果表明:脉宽小于或等于100 ps的激光作用于硅材料时,表层温度上升缓慢,会发生载流子效应,非傅里叶模型可以合理地反映这种现象;对于一般材料,载流子效应发生的条件是脉宽小于或等于材料热弛豫时间,此时应当用非傅里叶模型描述加热过程。     

Temperature prediction for CO2 laser heating of moving glass rods

This paper presents a heat transfer model to calculate the temperature field in moving glass rods heated by a CO₂ laser. Conduction and radiation heat transfer in radial and axial directions are taken into account in the current model. The Rosseland diffusion approximation is incorporated to analyze the radiation heat transfer in the glass rod. A two-band model is used to simulate the spectral property of the glass. Results of the simulation show that glass rods of sufficiently large optical thickness should be treated as a semitransparent medium for radiative transfer, and it is reasonably accurate to assume it to be opaque to CO₂ laser irradiation. It has been shown that the resulting temperature profile is strongly dependent on the laser parameters, i.e., the size of laser beam and the power of the laser. The diameter and speed of the moving glass rod are also important in determining the temperature field although the convective heat transfer coefficient between the glass rod and the environment has little effect.     

Thermal analysis of high-index-contrast grating (HCG)-based VCSEL

A 3-D thermal analysis of 870 nm high-index-contrast grating (HCG)-based vertical cavity surface emitting laser (VCSEL) by using finite volume method (FVM) is presented in this paper. The HCG-based VCSEL is modeled by applying a steady-state 3-D heat dissipation model. Temperature distribution profile and thermal resistance (R_th) of the device are investigated by inserting the heat source value into the thermal simulation. Also, this analysis is performed for a conventional VCSEL operating at the same wavelength and under the same injected current as well as the same geometric sizes. The analysis shows that the maximum temperature inside the HCG-based VCSEL is lower than that inside the conventional VCSEL.     

Comparative study on interactions between laser and arc plasma during laser-GTA welding and laser-GMA welding

This paper describes an investigation on differences in interactions between laser and arc plasma during laser-gas tungsten arc (LT) welding and laser-gas metal arc (LM) welding. The characteristics of LT heat source and LM heat source, such as plasma behavior, heat penetration ability and spectral information were comparably studied. Based on the plasma discharge theory, the interactions during plasma discharge were modeled and analyzed. Results show that in both LT and LM welding, coupling discharge between the laser keyhole plasma and arc happens, which strongly enhance the arc. But, the enhancing effect in LT welding is much more sensitive than that in LM welding when parameters are adjusted.     

Modeling and analysis of simultaneous laser transmission welding of polycarbonates using an FEM and RSM combined approach

In this paper, simultaneous laser transmission welding process is systematically investigated via process modeling, using an FEM and RSM combined approach. The objective of the present research is to study the effects of process parameters on the temperature field and weld bead dimensions. The thermal field is simulated by solving a three dimensional transient heat diffusion equation with temperature dependent material properties using the ANSYS^® multi-physics. Response surface methodology is then applied for developing mathematical models based on simulation results. The second order equations developed by RSM can predict the values of the responses with significant accuracy. The effect of parameters and their interactions on the responses are studied using the developed response surface models. The mathematical models are further used in search of the optimal process window for obtaining an acceptable weld. The graphical optimization results into a couple of overlay contours plots, which allow quick visual inspection of the area of feasible response values in the factor space to choose the favorable welding parameter combination.     

Prediction of weld strength and seam width for laser transmission welding of thermoplastic using response surface methodology

In the present work, a study is made to investigate the effects of process parameters, namely, laser power, welding speed, size of the laser beam and clamp pressure, on the lap-shear strength and weld-seam width for laser transmission welding of acrylic (polymethyl methacrylate), using a diode laser system. Response surface methodology (RSM) is employed to develop mathematical relationships between the welding process parameters and the output variables of the weld joint to determine the welding input parameters that lead to the desired weld quality. In addition, using response surface plots, the interaction effects of process parameters on the responses are analyzed and discussed. The statistical software Design-Expert v7 is used to establish the design matrix and to obtain the regression equations. The developed mathematical models are tested by analysis-of-variance (ANOVA) method to check their adequacy. Finally, a comparison is made between measured and calculated results, which are in good agreement. This indicates that the developed models can predict the responses adequately within the limits of welding parameters being used.     

Spatial and temporal thermal analysis of acousto-optic deflectors using finite element analysis model

Thermal effects greatly influence the optical properties of the acousto-optic deflectors (AODs). Thermal analysis plays an important role in modern AOD design. However, the lack of an effective method of analysis limits the prediction in the thermal performance. In this paper, we propose a finite element analysis model to analyze the thermal effects of a TeO₂-based AOD. Both transducer heating and acoustic absorption are considered as thermal sources. The anisotropy of sound propagation is taken into account for determining the acoustic absorption. Based on this model, a transient thermal analysis is employed using ANSYS software. The spatial temperature distributions in the crystal and the temperature changes over time are acquired. The simulation results are validated by experimental results. The effect of heat source and heat convection on temperature distribution is discussed. This numerical model and analytical method of thermal analysis would be helpful in the thermal design and practical applications of AODs.     

激光诱导间质热疗中生物组织的温度场研究

激光诱导间质热疗疗效评估的前提是必须获得准确的激光在不同功率、不同照射时间的生物组织温度场分布.利用多物理场直接耦合分析软件COMSOL Multiphysics构建了在组织光学参量不变情况下的三维有限元传热模型.该模型基于Pennes生物传热方程和轴对称高斯形状的激光光束热源方程,参量针对离体猪肝组织,考虑到了生物组织热物性密度、比热和热导率随温度变化的情况.仿真获得激光功率为0.77 W、0.95 W、1.23 W,照射时间为10~90 s,径向距离0~2 mm范围和轴向距离0~4 mm范围的温度场数据集.利用拟合算法,获得了自变量为激光功率、照射时间、径向距离和轴向距离的生物组织温度场分布模型.将功率为0.88 W和1.05 W时的结果与Pennes方程结果相比较,两者误差在5%以内.