Laser welding of copper–nickel alloys: a numerical and experimental analysis

Abstract Melt run trials were carried out on Cu–Ni bars using a CO2 laser source in order to analyse the effects of welding parameters (i.e. laser power, welding speed) on geometrical characteristics and on the microstructure of the bead. Experimental results were then used to determine the source parameters to be employed in a finite element model (FEM) of the welding process, with particular attention paid to the thermal field induced by the laser beam. A specific procedure, named 'automatic remeshing technique', was used in order to minimise the computation time. The aim was to create a reliable numerical model, suitable for the optimisation, in practical cases, of welding processes of these kinds of materials. A good correlation, in terms of predicted cooling rates, with the values calculated from SDAS measurements, was observed.

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