Numerical simulation and process parameter optimization of laser spot welding for ultra-thin sheets
Jin Peng, Sainan Xie, Yingkun Tian, Xingxing Wang, Xiaokai Yu, Nannan Chen, Zhipeng Yuan, Peng Han, Hongbo Xia, Pei Wang, Fuyun Liu, Jianhui Su, Caiwang Tan, Bo Wang, Zhihong Chen
Abstract
This study investigates laser spot welding of a 0.06 mm thick spring layer baseplate onto a thin substrate, employing numerical simulation via Simufact Welding(2020 version). Validation of the numerical model revealed a strong agreement between simulated and experimental molten pool diameters, with a minimal deviation of 5.8 %. The optimal welding strategy for a single feather-shaped component demonstrated that fixtures reduced post-weld deformation by ∼60 %, albeit with a 20 % increase in residual equivalent stress. Through an L9 (3 3 ) orthogonal experiment, laser power, cooling time, and welding time were identified as critical parameters influencing deformation, with the optimal combination being 20 W laser power, 1.8 s welding time, and 30 s cooling time. Furthermore, welding sequence analysis showed that a counterclockwise approach minimized deformation by 36 % compared to the clockwise sequence, while orthogonal sequences reduced deformation by 28 % relative to conventional methods. These results offer practical insights for enhancing the dimensional stability and mechanical performance of ultra-thin component welding.