Numerical modelling of laser welding pool thermal-dynamics and dissimilar materials mixing of cast iron, carbon-steel and nickel-alloy wire for weld crack prevention

Zhang, Renzhi; Nishimoto, Daichi; Ma, Ninshu; Lu, Fenggui; Suga, Tetsuo; Tabuchi, Takayuki; Shimada, Syuichi

doi:https://doi.org/10.1016/j.jmapro.2025.11.054

Numerical modelling of laser welding pool thermal-dynamics and dissimilar materials mixing of cast iron, carbon-steel and nickel-alloy wire for weld crack prevention

Zhang, Renzhi; Nishimoto, Daichi; Ma, Ninshu et al.

Journal of Manufacturing Processes, 2025, 156, 398-410

アクセス数:50件（2026-02-16 00:35 集計）

固定URL: https://hdl.handle.net/11094/103574

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タイトル	Numerical modelling of laser welding pool thermal-dynamics and dissimilar materials mixing of cast iron, carbon-steel and nickel-alloy wire for weld crack prevention
著者	著者名 Zhang, Renzhi
	著者名 Nishimoto, Daichi
	NRID 1000010263328 1000010263328 ORCID 0000-0002-8088-4154 0000-0002-8088-4154 researchmap permalink ma.ninshu ma.ninshu Scopus Author ID 36343934100 36343934100 著者名 Ma, Ninshu
	著者名 Lu, Fenggui
	ORCID 0000-0002-3759-2519 0000-0002-3759-2519 researchmap permalink TS2529 TS2529 Scopus Author ID 7201431992 7201431992 著者名 Suga, Tetsuo
	著者名 Tabuchi, Takayuki
	著者名 Shimada, Syuichi
キーワード等	Droplets transfer
	Keyhole dynamics
	Laser welding
	Materials mixing
	Three dissimilar materials
内容	Zhang R., Nishimoto D., Ma N., et al. Numerical modelling of laser welding pool thermal-dynamics and dissimilar materials mixing of cast iron, carbon-steel and nickel-alloy wire for weld crack prevention. Journal of Manufacturing Processes 156, 398 (2025); https://doi.org/10.1016/j.jmapro.2025.11.054.
抄録	To understand the prevention mechanism of weld cracks induced in laser welding dissimilar materials, carbon steel and cast iron with a nickel-alloy filler wire, it is necessary to investigate the melting pool thermal dynamics, keyhole mechanism and dissimilar materials mixing. In this study, a novel three-dimensional computational fluid dynamics (CFD) modelling on transient tracking of keyholes, transfer of molten wire droplets, mixing of filler and base metals, welding groove, coupled with conventional model of heat transfer, surface tension and recoil pressure, was developed. The simulated molten pool geometry and temperature field were compared with the experimental results, which confirmed the accuracy of the developed numerical model. The numerical results revealed that the keyhole underwent periodic oscillation and partial collapse, during which entrapped vapor formed transient bubbles that later escaped through buoyancy. The molten wire droplets significantly affected the flow field and local temperature, temporarily weakening Marangoni convection and altering keyhole stability. The nickel-alloy material concentrated primarily on the surface, then flowed into welding pool. After solidification, a large amount (65–75 %) of the nickel-alloy material kept in the upper half of the weld metal and a small amount distributed in the lower half zone. These distribution characteristics supplied a graded transition layer between the two dissimilar base metals benefiting to weld crack prevention. This research provided quantitative evaluation in visualizing the in-situ dynamic phenomena of dissimilar materials for laser welding process optimization.
出版者	Elsevier Ltd
収録物名	Journal of Manufacturing Processes
巻(号)	156
ページ	398-410
刊行年月	2025-12-26
言語	英語
ハンドルURL	https://hdl.handle.net/11094/103574
PISSN	15266125
関連情報 (isIdenticalTo)	DOI (出版社版) https://doi.org/10.1016/j.jmapro.2025.11.054
アクセス権	open access
権利情報	This article is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.
出版タイプ	Version of Record
カテゴリ	学術雑誌論文 Journal Article

資源タイプ	学術雑誌論文
ローカル資源タイプ	学術雑誌論文
DCMI資源タイプ	text
DCTERMS.bibliographicCitation	Journal of Manufacturing Processes. 2025, 156, p. 398-410
DC.title	Numerical modelling of laser welding pool thermal-dynamics and dissimilar materials mixing of cast iron, carbon-steel and nickel-alloy wire for weld crack prevention
DC.creator	Zhang, Renzhi
	Nishimoto, Daichi
	Ma, Ninshu
	Lu, Fenggui
	Suga, Tetsuo
	Tabuchi, Takayuki
	Shimada, Syuichi
DC.publisher	Elsevier Ltd
DC.language' scheme='DCTERMS.RFC1766	英語
DC.type' scheme='DCTERMS.DCMIType	text
DCTERMS.issued' scheme='DCTERMS.W3CDTF	2025-12-26
DC.identifier	https://doi.org/10.1016/j.jmapro.2025.11.054
DC.subject	Droplets transfer
	Keyhole dynamics
	Laser welding
	Materials mixing
	Three dissimilar materials
DC.description	Zhang R., Nishimoto D., Ma N., et al. Numerical modelling of laser welding pool thermal-dynamics and dissimilar materials mixing of cast iron, carbon-steel and nickel-alloy wire for weld crack prevention. Journal of Manufacturing Processes 156, 398 (2025); https://doi.org/10.1016/j.jmapro.2025.11.054.
DCTERMS.abstract	To understand the prevention mechanism of weld cracks induced in laser welding dissimilar materials, carbon steel and cast iron with a nickel-alloy filler wire, it is necessary to investigate the melting pool thermal dynamics, keyhole mechanism and dissimilar materials mixing. In this study, a novel three-dimensional computational fluid dynamics (CFD) modelling on transient tracking of keyholes, transfer of molten wire droplets, mixing of filler and base metals, welding groove, coupled with conventional model of heat transfer, surface tension and recoil pressure, was developed. The simulated molten pool geometry and temperature field were compared with the experimental results, which confirmed the accuracy of the developed numerical model. The numerical results revealed that the keyhole underwent periodic oscillation and partial collapse, during which entrapped vapor formed transient bubbles that later escaped through buoyancy. The molten wire droplets significantly affected the flow field and local temperature, temporarily weakening Marangoni convection and altering keyhole stability. The nickel-alloy material concentrated primarily on the surface, then flowed into welding pool. After solidification, a large amount (65–75 %) of the nickel-alloy material kept in the upper half of the weld metal and a small amount distributed in the lower half zone. These distribution characteristics supplied a graded transition layer between the two dissimilar base metals benefiting to weld crack prevention. This research provided quantitative evaluation in visualizing the in-situ dynamic phenomena of dissimilar materials for laser welding process optimization.
DC.rights	This article is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.
DC.format	103574
citation_title	Numerical modelling of laser welding pool thermal-dynamics and dissimilar materials mixing of cast iron, carbon-steel and nickel-alloy wire for weld crack prevention
citation_author	Zhang, Renzhi
	Nishimoto, Daichi
	Ma, Ninshu
	Lu, Fenggui
	Suga, Tetsuo
	Tabuchi, Takayuki
	Shimada, Syuichi
citation_publisher	Elsevier Ltd
citation_language	英語
citation_date	2025-12-26
citation_journal_title	Journal of Manufacturing Processes
citation_volume	156
citation_firstpage	398
citation_lastpage	410
citation_doi	https://doi.org/10.1016/j.jmapro.2025.11.054
citation_public_url	https://hdl.handle.net/11094/103574

Numerical modelling of laser welding pool thermal-dynamics and dissimilar materials mixing of cast iron, carbon-steel and nickel-alloy wire for weld crack prevention

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