Modelling of CO2 laser welding of magnesium alloys

Laser welding is an important joining process for magnesium alloys. These materials are being increasingly used in different applications such as in aerospace, aircraft, automotive, electronics, etc. To date, carbon dioxide (CO₂) neodymium-doped yttrium aluminum garnet (Nd:YAG) and the high power diode laser have been extensively used to investigate the weldability of magnesium alloys. The present work describes an analytical thermal model for the weldability of magnesium alloys (WE43) using an industrial (CO₂) laser source. The main target of the project is to present to the industrial community a simple and rapid tool for the determination of the penetration depth and the bead width as a function of both the incident laser power and welding speed. The proposed model is based on the Davis thermal approach, largely considered for the characterization of the average radius of the liquid zone, aiming at predicting the joint shape. Moreover, since during the welding process considered in this study, a protecting gas is used to avoid joint oxidation, both thermal convection and radiation phenomena in the welding area have been estimated and introduced in our model for a better characterization of the welding process. The obtained results have been compared to the experimental ones and a satisfactory correlation has been observed, indicating the reliability of the model developed in this study.