Impact of modeling assumptions on simulated melt pool dynamics compared to high-speed x-ray observations

Plewinski J, Hennig F, Forster C, Belousov S, Zakirov A, Korneev B, Spurk C, Hummel M, Olowinsky A, Beckmann F, Moosmann J, Schmidt M, Köstler H, Markl M (2026)

Publication Language: English

Publication Type: Book chapter / Article in edited volumes

Publication year: 2026

Edited Volumes: Mathematical Modelling of Weld Phenomena

Book Volume: 14

Pages Range: 195 - 223

DOI: 10.3217/978-3-99161-089-2-009

Abstract

Laser beam welding is a widely used advanced manufacturing process for joining metallic components across various industries. The process is prone to various defects, with solidification cracks being among the most common. Understanding the evolution of the solidification front, including temperature gradients, cooling rates and solidification velocity, is crucial to assess the conditions leading to crack formation. Direct experimental measurement of transient solidification conditions is extremely hallenging, while numerical simulations of melt pool dynamics provide complementary insights by predicting local solidification conditions.
In this work, we combine high-speed synchrotron X-ray imaging, which captures the evolution and velocity of the solidification front, with state-of-the-art numerical melt pool simulations that are able to provide local solidification conditions. Comparison of experiments and simulations reveals a mismatch in the quasi-stationary welding regime, primarily arising from the neglect of the gas phase in the simulations. Using a reduced model and simulation setup, we demonstrate how changes in modeling assumptions influence melt pool dynamics and shape. Our results highlight that, for deep-penetration laser welding, proper physical modeling of the vapor-filled keyhole is essential for accurate predictions of melt pool and solidification conditions.

Authors with CRIS profile

Involved external institutions

Rheinisch-Westfälische Technische Hochschule (RWTH) Aachen Germany (DE) Fraunhofer-Institut für Lasertechnik (ILT) Germany (DE) Helmholtz-Zentrum Hereon Germany (DE)

How to cite

APA:

Plewinski, J., Hennig, F., Forster, C., Belousov, S., Zakirov, A., Korneev, B.,... Markl, M. (2026). Impact of modeling assumptions on simulated melt pool dynamics compared to high-speed x-ray observations. In Mathematical Modelling of Weld Phenomena. (pp. 195 - 223).

MLA:

Plewinski, Jonas, et al. "Impact of modeling assumptions on simulated melt pool dynamics compared to high-speed x-ray observations." Mathematical Modelling of Weld Phenomena. 2026. 195 - 223.

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