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Numerical Investigation of Laser Power and Speed Effects on Weld Pool Geometry and Thermal Distribution

International Journal of Applied Physics
© 2026 by SSRG - IJAP Journal
Volume 13 Issue 1
Year of Publication : 2026
Authors : Mohammed Abdulbasit Saleem Abdulhussein
10.14445/23500301/IJAP-V13I1P101

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How to Cite?

Mohammed Abdulbasit Saleem Abdulhussein, "Numerical Investigation of Laser Power and Speed Effects on Weld Pool Geometry and Thermal Distribution," SSRG International Journal of Applied Physics, vol. 13,  no. 1, pp. 1-5, 2026. Crossref, https://doi.org/10.14445/23500301/IJAP-V13I1P101

Abstract:

The study is a high-fidelity numerical study on the relationship between laser power and scanning speed, thermal distribution, and morphological change of the weld pool during laser processing. It has created a multi-physics model that is a combination of three-dimensional transient heat transfer, Navier-Stokes fluid dynamics, and non-equilibrium solidification kinetics. The model takes into consideration essential physical processes, such as Marangoni convection, buoyancy-led flow, and an enthalpy-porosity approach to phase-change. The results show non-linear switching of conduction to keyhole mode with increased power of the laser, and this essentially changes the depth-to-width aspect ratio of the zone of fusion. In addition, the scanning speed has been found to be the main controller of the cooling rate, in which large velocities result in severe undercooling and consequential microstructural refinement within the rear of the pool. Comparison with known experimental data proves that the predictive accuracy is at a high level, and the error measure is lower than seven percent. The work has given important information on how to optimize the welding parameters of lasers to achieve structural homogeneity and reduce the residual stresses in the high-tech metallic components.

Keywords:

Laser Welding, Numerical Simulation, Melt Pool Dynamics, Thermal Distribution, Marangoni Effect, Solidification Kinetics, Heat Affected Zone, Keyhole Mode.

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