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<p>Audible sounds are the valuable signals for real-time monitoring the quality of laser welding. However, the mechanism of audible sound generation during the keyhole laser welding is unknown. This study investigated the acoustic signal distributions and variations during Ti-6Al-4&#xa0;V laser oscillation welding process through numerical simulation. Firstly, a multi-physics thermal-fluid dynamics model was established to study the keyhole formation and dynamic evolution process. Then a keyhole acoustic field model was developed to analyze the sound signal distributions inside of keyhole and the variations of them under different keyhole dynamic shapes. The study found that under laser oscillation conditions, the attenuation of the sound pressure level inside the keyhole is more pronounced. It was also found that the sound pressure level is inversely proportional to the keyhole depth, although the irregular shape of the keyhole weakens this inverse relationship. Furthermore, as the laser oscillation frequency increases, this weakening effect becomes progressively more evident.</p> Graphical Abstract <p></p>

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Numerical simulation of audible sound generation from keyhole dynamics in oscillation laser welding of Ti-6Al-4V alloy

  • 期刊论文

  • 发表日期：

    2026年4月8日

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  • Donglin Tao,
  • Yanfeng Gao,
  • Yunqian Li,
  • Kejian Deng,
  • Pengxu Wang,
  • Hua Zhang

摘要

Audible sounds are the valuable signals for real-time monitoring the quality of laser welding. However, the mechanism of audible sound generation during the keyhole laser welding is unknown. This study investigated the acoustic signal distributions and variations during Ti-6Al-4 V laser oscillation welding process through numerical simulation. Firstly, a multi-physics thermal-fluid dynamics model was established to study the keyhole formation and dynamic evolution process. Then a keyhole acoustic field model was developed to analyze the sound signal distributions inside of keyhole and the variations of them under different keyhole dynamic shapes. The study found that under laser oscillation conditions, the attenuation of the sound pressure level inside the keyhole is more pronounced. It was also found that the sound pressure level is inversely proportional to the keyhole depth, although the irregular shape of the keyhole weakens this inverse relationship. Furthermore, as the laser oscillation frequency increases, this weakening effect becomes progressively more evident.

Graphical Abstract