本研究利用OpenFOAM建立三維數值模型探討新型熱源模型對銲接熔池的流場狀況及成型，主要利用多相流模型以辨別熔池與空氣之交界面，而為了準確模擬出熔池的流動現象，模擬中加入反衝壓力(Recoil force)、馬倫格尼力(Marangoni force)、表面張力(Surface tension)於熔池中，以及使用固液化模型、蒸發潛熱模型以近似現實的雷射銲接，且在鎖孔(Keyhole)條件下雷射於鎖孔內部進行多重反射(Multiple reflections)的緣故，鎖孔下鑽越深會導致材料吸收越多的雷射能量，因此在模擬中使用的雷射吸收率不應該使用定值進行模擬。
在以往的研究中，雷射吸收率會因為金屬材料、工況而有所不同，本文章收集了許多實驗以及模擬中雷射吸收率與熔池深度之結果，將這些資料彙整並擬合出兩者關係的經驗曲線，並以此關係式套入本研究之計算，可以依照鎖孔之深度來決定出當下的雷射吸收率。本研究另開發一套自適應體熱源模型，對體熱源參數進行數值測試並且與無因次焓做擬合找出兩者之間的關係。進行數值實驗後發現雷射工況的Fo數 (Fourier number) 亦會影響熔池之尺寸，因此本研究將熔池尺寸對無因次焓以及Fo數進行統整。在這樣的歸納之下，後人可以免去對吸收率依照工況而變動，降低時間成本以及數值實驗即可利用此模擬預測直掃式雷射銲接之熔池寬度以及深度。除了直掃式雷射銲接之外，本研究也將擬合之體熱源參數套用至圓形擺盪型雷射銲接進行燒熔預測熔池尺寸後，認為此熱源模型亦能夠適用於該擺盪型式雷射銲接之模擬。

This study employs OpenFOAM to establish a three-dimensional numerical model to explore the flow field and formation of welding molten pools using a novel heat source model. The study primarily utilizes multiphase flow modeling to distinguish the interface between the molten pool and air. To accurately simulate the flow phenomena within the molten pool, the simulation incorporates recoil force, Marangoni force, and surface tension into the molten pool. Additionally, solidification and latent heat of evaporation models are used to approximate realistic laser welding conditions. Under keyhole conditions, multiple reflections of the laser within the keyhole lead to increased material absorption of laser energy as the keyhole is drilled deeper. Therefore, the simulation avoids using a constant laser absorption rate and adapts it based on the keyhole depth.
In previous research, laser absorption rates varied due to different metal materials and operating conditions. This study collects experimental and simulated results of laser absorption rates and molten pool depth, synthesizing this data to fit empirical curves that describe the relationship between the two. This relationship is incorporated into the calculations of the current study, allowing for the determination of laser absorption rates based on keyhole depth. The study introduces an adaptive volumetric heat source model, subjecting heat source parameters to numerical tests and fitting them with dimensionless enthalpy to establish their relationship. Through numerical experiments, it is discovered that the Fourier number of the laser condition also influences the size of the molten pool. Therefore, the study integrates molten pool size with dimensionless enthalpy and Fourier number.
This generalization enables future researchers to predict the width and depth of molten pools in straight-line laser welding without adjusting absorption rates based on operating conditions, thereby reducing time and cost in numerical experiments. Additionally, the heat source parameters fitted in this study are applied to predict molten pool size in circular oscillation-type laser welding, suggesting the applicability of this heat source model to simulations of such oscillation-type welding processes.

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