Calibration of Finite Element Model of Titanium Laser Welding by Fractional Factorial Design

Abstract

This paper focuses on the calibration of heat source parameters to reproduce temperatures and distortions in welded joints. Specifically, the proposed methodology, which combines the Finite Element Method and Design of Experiments, is applied to calibrate a T-joint dissimilar titanium laser welding process. The thermal problem is addressed using a 3D transient model with a Conical Gaussian heat flux, and the mechanical problem is tackled using a 3D elastic-plastic model. A Fractional-Factorial Design is performed to define a set of thermo-mechanical uncoupled models. Finally, optimal parameter combinations that replicate experimental data are identified. This methodology allows automation that replaces the traditional trial and error process, which frequently does not provide good results, is an exhausting task and requires a dubious amount of time.