About this Abstract |
| Meeting |
2027 TMS Annual Meeting & Exhibition
|
| Symposium
|
Advanced Real Time Imaging for Materials Science and Processing: 10th Anniversary
|
| Presentation Title |
Transient Keyhole Dynamics and Defects Formation during High-power-density Laser Spot Welding of Aluminium |
| Author(s) |
Jiahui Zhang, Zhengrui Tao, Kwan Kim, Shishira Bhagavath, Yuhan Wang, Chuzhe Song, Sebastian Marussi, Andrey Gorskiy, Aleksandr Oreshkin, Alexander Rack, Tristan Fleming, Emma Howard, Iurii Markushov, Peter D Lee, Chu Lun Alex Leung |
| On-Site Speaker (Planned) |
Jiahui Zhang |
| Abstract Scope |
High-power-density laser spot welding enables deep penetration and localized energy delivery for precision joining, making it attractive in advanced manufacturing sectors. Yet, the ultra-deep keyhole dynamics and defect formation in this process that govern weld quality remain insufficiently understood. Here, we combine MHz-scale synchrotron X-ray imaging with multiphysics computational fluid dynamics simulations to resolve transient keyhole evolution and defect formation during welding. During initial drilling, localized energy absorption and evaporation-driven recoil pressure cause rapid penetration, upward melt jetting, and protuberance-mediated spatter ejection. Following drilling, the keyhole entered a quasi-steady oscillatory regime characterized by recurrent wall bulging and collapse, during which two distinct pore-formation pathways were identified. After laser shut-off, recoil-pressure loss triggers keyhole collapse and fragmentation into trapped pores. By resolving and quantifying defect formation in ultra-deep keyhole regime, this work establishes a mechanistic basis for controlling porosity and high-quality precision laser spot welding under extreme power-density conditions. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Computational Materials Science & Engineering, Aluminum |