A finite element (FE) approach is developed to investigate the laser spot welding (LSW) of flat-plate solar absorbers and the stress and distortion fields that develop after fabrication and during operation. Numerical calculations at two different levels are carried out. At a microscopic scale, the details of a spot weld are analyzed. At a macroscopic level, a global approach is used to simulate the joining of the pipeline to the absorber plate and the “restoration” (flattening) process of the absorber. The simulated welding-induced distortion is compared with experimental measurements. The thermomechanical behavior of a solar absorber under working conditions is also studied and operational stresses and the critical locations for structural failure are reported.
Issue Section:
Research Papers
References
1.
Kalogirou
, S. A.
, 2004
, “Solar Thermal Collectors and Applications
,” Prog. Energy Combust.
, 30
(3
), pp. 231
–295
.10.1016/j.pecs.2004.02.0012.
Agnihotri
, O. P.
, and Gupta
, B. K.
, 1981
, Solar Selective Surfaces
, Wiley
, New York
.3.
Duffie
, J. A.
, and Beckmann
, W. A.
, 2006
, Solar Engineering of Thermal Processes
, Wiley
, New York
.4.
Dürr
, U.
, Holtz
, R.
, Jokiel
, M.
, Liebers
, R.
, and Lavoie
, D.
, 2004
, “Advanced Micro-Welding Strategies With Pulsed Nd:YAG Lasers
,” Proceedings of 23rd International Congress on Applications of Laser and Electro-Optics (ICALEO’04)
, San Francisco, CA, Paper No: P109.5.
Schubert
, E.
, Klassen
, M.
, Zerner
, I.
, Walz
, C.
, and Sepold
, G.
, 2001
, “Light-Weight Structures Produced by Laser Beam Joining for Future Applications in Automobile and Aerospace Industry
,” J. Mater. Process. Technol.
, 115
(1
), pp. 2
–8
.10.1016/S0924-0136(01)00756-76.
Mai
, T. A.
, and Spowage
, A. C.
, 2004
, “Characterisation of Dissimilar Joints in Laser Welding of Steel-Kovar, Copper-Steel and Copper-Aluminium
,” Mater. Sci. Eng. A
, 374
(1–2
), pp. 224
–233
.10.1016/j.msea.2004.02.0257.
Brandal
, G.
, Satoh
, G.
, Yao
, Y. L.
, and Naveed
, S.
, 2013
, “Beneficial Interface Geometry for Laser Joining of NiTi to Stainless Steel Wires
,” ASME J. Manuf. Sci. Eng.
, 135
(6
), p. 061006
.10.1115/1.40254958.
Frewin
, M. R.
, and Scott
, D. A.
, 1999
, “Finite Element Model of Pulsed Laser Welding
,” Weld. J.
, 78
(1), pp. 15s
–22s
.9.
Chang
, W. S.
, and Na
, S. J.
, 2001
, “Prediction of Laser Spot Weld Shape by Numerical Analysis and Neural Network
,” Metall. Mater. Trans. B
, 32
(4
), pp. 723
–731
.10.1007/s11663-001-0126-310.
De
, A.
, Maiti
, S. K.
, Walsh
, C. A.
, and Bhadeshia
, H. K. D. H.
, 2003
, “Finite Element Simulation of Laser Spot Welding
,” J. Sci. Technol. Weld. Joining
, 8
(5
), pp. 377
–384
.10.1179/13621710322500557011.
Balasubramanian
, K. R.
, Siva Shanmugam
, N.
, Buvanashekaran
, G.
, and Sankaranarayanasamy
, K.
, 2008
, “Numerical and Experimental Investigation of Laser Beam Welding of AISI 304 Stainless Steel Sheet
,” Adv. Produc. Engineer. Manag.
, 3
(2), pp. 93
–105
.12.
Sabbaghzadeh
, J.
, Azizi
, M.
, and Javad Torkamany
, M.
, 2008
, “Numerical and Experimental Investigation of Seam Welding With a Pulsed Laser
,” Opt. Laser Technol.
, 40
(2
), pp. 289
–296
.10.1016/j.optlastec.2007.05.00513.
Lee
, D.
, and Kannatey-Asibu
, E.
, 2008
, “Numerical Analysis on the Feasibility of Laser Microwelding of Metals by Femtosecond Laser Pulses Using Abaqus
,” ASME J. Manuf. Sci. Eng.
, 130
(6
), p. 061014
.10.1115/1.300632114.
Lee
, D.
, and Kannatey-Asibu
, E.
, 2009
, “Numerical Analysis of Ultrashort Pulse Laser-Material Interaction Using Abaqus
,” ASME J. Manuf. Sci. Eng.
, 131
(2
), p. 021005
.10.1115/1.307586915.
Shanmugam
, N. S.
, Buvanashekaran
, G.
, Sankaranarayanasamy
, K.
, and Ramesh Kumar
, S.
, 2010
, “A Transient Finite Element Simulation of the Temperature and Bead Profiles of T-Joint Laser Welds
,” J. Mater. Des.
, 31
(9
), pp. 4528
–4542
.10.1016/j.matdes.2010.03.05716.
Tan
, W.
, Bailey
, N. S.
, and Shin
, Y. C.
, 2012
, “Numerical Modeling of Transport Phenomena and Dendritic Growth in Laser Spot Conduction Welding of 304 Stainless Steel
,” ASME J. Manuf. Sci. Eng.
, 134
(4
), p. 041010
.10.1115/1.400710117.
Ma
, C.
, Vadali
, M.
, Duffie
, N. A.
, Pfefferkorn
, F. E.
, and Li
, X.
, 2013
, “Melt Pool Flow and Surface Evolution During Pulsed Laser Micro Polishing of Ti6Al4V
,” ASME J. Manuf. Sci. Eng.
, 135
(6
), p. 061023
.10.1115/1.402581918.
Sammons
, P. M.
, Bristow
, D. A.
, and Landers
, R. G.
, 2013
, “Height Dependent Laser Metal Deposition Process Modeling
,” ASME J. Manuf. Sci. Eng.
, 135
(5
), p. 054501
.10.1115/1.402506119.
Shi
, B.
, and Attia
, H.
, 2013
, “Integrated Process of Laser-Assisted Machining and Laser Surface Heat Treatment
,” ASME J. Manuf. Sci. Eng.
, 135
(6
), p. 061021
.10.1115/1.402583220.
Xue
, Z.
, Hu
, S.
, Zuo
, D.
, Cai
, W.
, Lee
, D.
, and Kannatey-Asibu
, E.
, 2013
, “Molten Pool Characterization of Laser Lap Welded Copper and Aluminum
,” J. Phys. D: Appl. Phys.
, 46
(49), p. 495501
.10.1088/0022-3727/46/49/49550121.
Zhang
, Y.
, Li
, S.
, Chen
, G.
, and Mazumder
, J.
, 2013
, “Experimental Observation and Simulation of Keyhole Dynamics During Laser Drilling
,” Opt. Laser Technol.
, 48
, pp. 405
–414
.10.1016/j.optlastec.2012.10.03922.
Mazar Atabaki
, M.
, Nikodinovski
, M.
, Chenier
, P.
, Ma
, J.
, Liu
, W.
, and Kovacevic
, R.
, 2014
, “Experimental and Numerical Investigations of Hybrid Laser Arc Welding of Aluminum Alloys in the Thick T-Joint Configuration
,” Opt. Laser Technol.
, 59
, pp. 68
–92
.10.1016/j.optlastec.2013.12.00823.
Kang
, D.-H.
, Son
, K.-J.
, and Yang
, Y.-S.
, 2001
, “Analysis of Laser Weldment Distortion in the EDFA LD Pump Packaging
,” Finite Elem. Anal. Des.
, 37
(9
), pp. 749
–760
.10.1016/S0168-874X(01)00042-724.
Tsirkas
, S. A.
, Papanikos
, P.
, and Kermanidis
, Th.
, 2003
, “Numerical Simulation of the Laser Welding Process in Butt-Joint Specimens
,” J. Mater. Process. Technol.
, 134
(1
), pp. 59
–69
.10.1016/S0924-0136(02)00921-425.
Darcourt
, C.
, Roelandt
, J. M.
, Rachik
, M.
, Deloison
, D.
, and Journet
, B.
, 2004
, “Thermomechanical Analysis Applied to the Laser Beam Welding Simulation of Aeronautical Structures
,” J. Phys. IV
, 120
, pp. 785
–792
.10.1051/jp4:200412009126.
Spina
, R.
, Tricarico
, L.
, Basile
, G.
, and Sibillano
, T.
, 2007
, “Thermo-Mechanical Modeling of Laser Welding of AA5083 Sheets
,” J. Mater. Process. Technol.
, 191
(1–3
), pp. 215
–219
.10.1016/j.jmatprotec.2007.03.08727.
Moraitis
, G. A.
, and Labeas
, G. N.
, 2008
, “Residual Stress and Distortion Calculation of Laser Beam Welding for Aluminum Lap Joints
,” J. Mater. Process. Technol.
, 198
(1–3
), pp. 260
–269
.10.1016/j.jmatprotec.2007.07.01328.
Martinson
, P.
, Daneshpour
, S.
, Koçak
, M.
, Riekehr
, S.
, and Staron
, P.
, 2009
, “Residual Stress Analysis of Laser Spot Welding of Steel Sheets
,” J. Mater. Des.
, 30
(9
), pp. 3351
–3359
.10.1016/j.matdes.2009.03.04129.
Zain-Ul-Abdein
, M.
, Nelias
, D.
, Jullien
, J. F.
, and Deloison
, D.
, 2009
, “Prediction of Laser Beam Welding-Induced Distortions and Residual Stresses by Numerical Simulation for Aeronautic Application
,” J. Mater. Process. Technol.
, 209
(6
), pp. 2907
–2917
.10.1016/j.jmatprotec.2008.06.05130.
Han
, Q.
, Kim
, D.
, Kim
, D.
, Lee
, H.
, and Kim
, N.
, 2012
, “Laser Pulsed Welding in Thin Sheets of Zircaloy-4
,” J. Mater. Process. Technol.
, 212
(5
), pp. 1116
–1122
.10.1016/j.jmatprotec.2011.12.02231.
Stevens
, V.
, Celentano
, D.
, Ramos-Grez
, J.
, and Walczak
, M.
, 2012
, “Experimental and Numerical Analysis of Low Output Power Laser Bending of Thin Steel Sheets
,” ASME J. Manuf. Sci. Eng.
, 134
(3
), p. 031010
.10.1115/1.400580732.
Marimuthu
, S.
, Eghlio
, R. M.
, Pinkerton
, A. J.
, and Li
, L.
, 2013
, “Coupled Computational Fluid Dynamic and Finite Element Multiphase Modeling of Laser Weld Bead Geometry Formation and Joint Strengths
,” ASME J. Manuf. Sci. Eng.
, 135
(1
), p. 011004
.10.1115/1.402324033.
Tan
, H.
, and Yao
, Y. L.
, 2013
, “Laser Joining of Continuous Glass Fiber Composite Preforms
,” ASME J. Manuf. Sci. Eng.
, 135
(1
), p. 011010
.10.1115/1.402327034.
Voothaluru
, R.
, Liu
, C. R.
, and Cheng
, G. J.
, 2013
, “Finite Element Analysis of the Variation in Residual Stress Distribution in Laser Shock Peening of Steels
,” ASME J. Manuf. Sci. Eng.
, 134
(6
), p. 061010
.10.1115/1.400778035.
Wang
, H.
, Hsu
, S.-T.
, Tan
, H.
, Yao
, Y. L.
, Chen
, H.
, and Azer
, M. N.
, 2013
, “Predictive Modeling for Glass-Side Laser Scribing of Thin Film Photovoltaic Cells
,” ASME J. Manuf. Sci. Eng.
, 135
(5
), p. 051004
.10.1115/1.402481836.
Xu
, W.
, Zhang
, L. C.
, and Wang
, X.
, 2013
, “Laser Bending of Silicon Sheet: Absorption Factor and Mechanisms
,” ASME J. Manuf. Sci. Eng.
, 135
(6
), p. 061005
.10.1115/1.402557937.
Yilbas
, B. S.
, and Akhtar
, S.
, 2013
, “Laser Welding of AISI 316 Steel: Microstructural and Stress Analysis
,” ASME J. Manuf. Sci. Eng.
, 135
(3
), p. 031018
.10.1115/1.402415538.
Farahmand
, P.
, and Kovacevic
, R.
, 2014
, “An Experimental-Numerical Investigation of Heat Distribution and Stress Field in Single- and Multi-Track Laser Cladding by a High-Power Direct Diode Laser
,” Opt. Laser Technol.
, 63
, pp. 154
–168
.10.1016/j.optlastec.2014.04.01639.
Abaqus/Standard,
2012
, Version 6.12, Abaqus, Inc.40.
Material Properties Database (MPDB),
2012
, Version 7.57, JAHM Software, Inc.41.
Pells
, G. P.
, and Shiga
, M.
, 1969
, “The Optical Properties of Copper and Gold as a Function of Temperature
,” J. Phys. C: Solid State Phys.
, 2
(10
), pp. 1835
–1846
.10.1088/0022-3719/2/10/31842.
Mathewson
, A. G.
, and Myers
, H. P.
, 1972
, “Optical Absorption in Aluminium and the Effect of Temperature
,” J. Phys. F: Met. Phys.
, 2
(2
), pp. 403
–415
.10.1088/0305-4608/2/2/03043.
Chalmers
, B.
, 1964
, Principles of Solidification
, Willey
, New York
.44.
Andersson
, J. O.
, Helander
, T.
, Höglund
, L.
, Shi
, P. F.
, and Sundman
, B.
, 2002
, “Thermo-Calc and DICTRA, Computational Tools for Materials Science
,” Calphad
, 26
(2), pp. 273
–312
.10.1016/S0364-5916(02)00037-845.
Deng
, D.
, 2009
, “FEM Prediction of Welding Residual Stress and Distortion in Carbon Steel Considering Phase Transformation Effects
,” J. Mater. Des.
, 30
(2
), pp. 359
–366
.10.1016/j.matdes.2008.04.05246.
Simo
, J. C.
, and Rifai
, M. S.
, 1990
, “A Class of Mixed Assumed Strain Methods and the Method of Incompatible Modes
,” Int. J. Numer. Meth. Eng.
, 29
(8
), pp. 1595
–1638
.10.1002/nme.1620290802Copyright © 2015 by ASME
You do not currently have access to this content.
