Smoothed Particle Hydrodynamics (SPH) modelling of transient heat transfer in pulsed laser ablation of Al and associated free-surface problems

A Smoothed Particle Hydrodynamics (SPH) numerical model is developed to simulate pulsed-laser ablation processes for micro-machining. Heat diffusion behaviour of a specimen under the action of nanosecond pulsed lasers can be described analytically by using complementary error function solutions of second-order differential equations. However, their application is limited to cases without loss of material at the surface. Compared to conventional mesh-based techniques, as a novel meshless simulation method, SPH is ideally suited to applications with highly non-linear and explosive behaviour in laser ablation. However, little is known about the suitability of using SPH for the modelling of laser-material interactions with multiple phases at the micro scale. The present work investigates SPH modelling of pulsed-laser ablation of aluminium where the laser is applied directly to the free-surface boundary of the specimen. Having first assessed the performance of standard SPH surface treatments for functions commonly used to describe laser heating, the heat conduction behaviour of a new SPH methodology is then evaluated through a number of test cases for single- and multiple-pulse laser heating of aluminium showing excellent agreement when compared with an analytical solution. Simulation of real ablation processes, however, requires the model to capture the removal of material from the surface and its subsequent effects on the laser heating process. Hence, the SPH model for describing the transient behaviour of nanosecond laser ablation is validated with a number of experimental and reference results reported in the literature. The SPH model successfully predicts the material ablation depth profiles over a wide range of laser fluences 4–23 J/cm2 and pulse durations 6–10 ns, and also predicts the transient behaviour of the ejected material during the laser ablation process. Unlike conventional mesh-based methods, the SPH model was not only able to provide the thermo-physical properties of the ejected particles, but also the effect of the interaction between them as well as the direction and the pattern of the ejection

The effects of short pulse laser surface cleaning on porosity formation and reduction in laser welding of aluminium alloy for automotive component manufacture

Laser welding of aluminium alloys typically results in porosity in the fusion zones, leading to poor mechanical and corrosion performances. Mechanical and chemical cleaning of surfaces has been used previously to remove contaminants for weld joint preparations. However, these methods are slow, ineffective (e.g. due to hydrogen trapping) or lead to environmental hazards. This paper reports the effects of short pulsed laser surface cleaning on porosity formation and reduction in laser welding of AC-170PX (AA6014) aluminium sheets (coated with Ti/Zr and lubricated using a dry lubricant AlO70) with two types of joints: fillet edge and flange couch, using an AA4043 filler wire for automotive component assembly. The effect of laser cleaning on porosity reduction during laser welding using a filler wire has not been reported before. In this work, porosity and weld fusion zone geometry were examined prior to and after laser cleaning. The nanosecond pulsed Nd:YAG laser cleaning was found to reduce porosity significantly in the weld fusion zones. For the fillet edge welds, porosity was reduced to less than 0.5% compared with 10–80% without laser cleaning. For flange couch welds, porosity was reduced to 0.23–0.8% with laser cleaning from 0.7% to 4.3% without laser cleaning. This has been found to be due to the elimination of contaminations and oxide layers that contribute to the porosity formation. The laser cleaning is based on thermal ablation