Modelling and validation of multiple reflections for enhanced laser welding

The effects of multiple internal reflections within a laser weld joint as functions of joint geometry and processing conditions have been characterized. A computer-based ray tracing model is used to predict the reflective propagation of laser beam energy focused into the narrow gap of a metal joint for the purpose of predicting the location of melting and coalescence to form a weld. Quantitative comparisons are made between simulation cases. Experimental results are provided for qualitative model validation. This method is proposed as a way to enhance process efficiency and design laser welds which display deep penetration and high depth-to-width aspect ratios without high powered systems or keyhole mode melting.