A Case Study of a Laser Beam Welding Model for the Welding of Inconel 718 Sheets of a Dissimilar Thickness

Laser beam welding (LBW) is a highly demanded process for premium-quality joints in aeronautic, energy, or industrial sectors, where flexibility and low-heat-affected zones are required. One of the main applications of LBW in the near future is expected to be the welding of new turbine engine components, which are typically made of Nickel-based superalloys. However, parameter setup is time- and resource-consuming, where experiment-based methods are typically employed. Therefore, the process development is far from an efficient resource utilization. In the present work, an LBW numerical model is developed and experimentally validated through a machine-integrated monitoring system. The LBW model is based on solving the heat transfer problem produced by the laser and provides the resulting temperature field, as well as the weld bead dimensions. The model includes a variable heat source that automatically adapts to the welding regime, conduction, or keyhole. For the model validation, two Inconel 718 sheets of different thicknesses are butt-welded and an error of around 10% is obtained, which ensures the validity of the model.