An approach to modelling defocusing and keyhole reflectivity in keyhole laser processes

Keyhole laser-based processes have been adopted widely due to the high-quality welds and cuts that they produce and the accurately controlled dimensions of the end part. Fast-running simulation tools are required in order to estimate the dependence of process outputs, efficiency, and stability on the process variables. This work presents a fast-running simulation tool for keyhole laser-based processes with inert or no assisting gas that takes into account the effect of laser beam defocusing and the alteration of the effective reflectivity of the material due to the keyhole cavity. The model is built upgrading a successful model for the thermal phenomena based on finite differences and the enthalpy method. The presented model is compared to experimental results for the laser cutting process with both CO \(_2\) $_2^{}$ and fiber laser sources and inert assisting gas. The model accurately predicts cutting depth and kerf, heat-affected zone width, and the dependence of the cutting depth on the position of the focal plane. The model manages to achieve reduced computational time enabling its utilization in process digital twins.