FEM-Based Conductive Heat Transfer Analytical Description of Solidification Rate and Temperature Gradient during Lateral Laser Beam Oscillation Welding of Aluminum Alloy

This study investigates the feasibility of utilizing the finite element method (FEM)-based conductive heat transfer (CHT) analysis simulation to determine temperature gradients and solidification rates at the solid–liquid interface during laser beam oscillation welding. By comparing experimental observations with FEM-based CHT analysis, the underlying microstructural evolution and grain formation during welding were examined. FEM-based CHT enables the calculation of temperature gradients (G) and solidification rates (R), offering insights into the formation of equiaxed structures, which are crucial for suppressing hot cracking. Columnar-to-equiaxed structure transition thresholds, such as G/R and G3/R, accurately predict the emergence of fully equiaxed grain structures, validated by electron backscatter diffraction. This research provides valuable insights into temperature gradients and solidification rates in oscillation welding, guiding process design for achieving refined equiaxed structures and minimizing hot cracks.