Power-velocity optimization

The following application — based on the Rosenthal solution for a moving point heat source in steady state on a semi-infinite solid — computes the maximum allowable heat source velocity and the corresponding power given the initial (or preheating) temperature, material properties, and two geometric constraints on the melt isotherm:

the half-width or penetration of the melted zone must be greater than or equal to the input value This is generally a direct or indirect process requirement to ensure adhesion (but also limit porosity in the case of Additive Manufacturing).
the melt pool length-to-width aspect ratio must be lower than or equal to the input value. This limits the risk of BCM humping (i.e., the formation of periodic beadlike protuberances instead of a uniform weld bead) and hot cracking.

Mattia Moda

Parameters and properties

Min. penetration (mm):

Thermal conductivity (W/m/K):

Max. velocity:

Max. aspect ratio:

Thermal diffusivity (mm²/s):

Opt. power:

Preheating (K):

Melting point (K):

Fix axes:

Please note that the above feasible region is unbounded simply because the considered mathematical model is not affected by a generalized constraint on the transverse aspect ratio of the melt pool, which instead is always present in practice due to the conduction to keyhole mode transition. For a full theoretical explanation and further details, you can refer to my doctoral thesis.