The effects of turbulence on molten pool transport during melting and solidification processes in continuous conduction mode laser welding of copper-nickel dissimilar couple

The melting and solidification stages of a continuous copper-nickel dissimilar metal conduction mode laser welding have been simulated numerically in this study. The heat, mass and momentum transports in molten metal pool have been analysed using both laminar and turbulent flow models separately for the same process parameters. The phase change aspects related to solidification and melting are accounted for by a modified enthalpy-porosity technique while the turbulent transport is modelled by a high Reynolds number k-ε model. It has been observed that temperature fields obtained from both laminar and turbulent transport simulations are qualitatively similar to each other. The molecular thermal diffusivity of the molten metal mixture is found to be in the same order of magnitude as eddy thermal diffusivity, as a result of which the thermal field gets marginally affected by fluid turbulence. By contrast, eddy viscosity remains much greater than molecular viscosity, which leads to greater amount of momentum diffusion in the case of a turbulent molten metal pool, in comparison to that obtained from the corresponding laminar simulation. This is reflected in the reduction in maximum velocity magnitude in the turbulent simulation in comparison to the maximum velocity obtained from laminar simulation. In the case of species transport, the turbulent mass diffusivity is found to be about 107-108 times greater than molecular mass diffusivity. As a result, the species field in turbulent simulation shows characteristics of better mixing between two dissimilar molten metals than the species field obtained using the laminar transport model. The species distribution obtained from turbulent transport is shown to be in better agreement with experimental data reported in literature than the corresponding mass fraction distribution obtained from laminar simulation. It is also found that species distribution in the molten pool is principally determined by advective and diffusive transport during the melting stage and species transport by advection and eddy diffusion in turbulent pool increasingly weakens with decreasing temperature during the cooling following the laser melting stage.