A model of deep penetration laser welding based on calculation of the keyhole profile

A model describing the process of deep-penetration laser welding has been developed by calculating the keyhole profile using a point-by-point determination of the energy balance at the keyhole wall. A formula for heat conduction was derived from the model of a moving line source of heat. The various absorption mechanisms were modelled. The corresponding absorbed power transferred to the keyhole wall balances the conduction losses, which yields the local inclination of the wall. The thermodynamics and the flow of metal vapour inside the keyhole have been calculated. Accordingly, beam damping due to the plasma plume above the workpiece and the mean plasma absorption coefficient in the keyhole could be estimated. The keyhole profile tends to a geometry that distributes the major part of the beam to the front wall owing to higher conduction losses at the upstream side. The reasons for decreasing energy absorption with increasing welding speed are discussed.