The Theory of Laser Materials Processing : Heat and Mass Transfer in Modern Technology Hardback

Edited by John Dowden

Part of the Springer Series in Materials Science series

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Theuseoflasersinmaterialsprocessinghasbecomewidespreadinrecent years,sothatanunderstandingofthenatureofheatandmasstransferin thisbranchofmoderntechnologyisofincreasingimportance.

Theaimofthe authorsofthisbookistoconcentrateonthephysicalprocesses;thesecanbe developedfromamathematicalpointofview,orfromdirectexperimental- derivedobservation.

Thetwoapproachesarecomplementary;eachcanprovide insightsandthesynthesisofthetwocanleadtoaverypowerfulunderstanding oftheprocessesinvolved.

Mathematicalmodellingofphysicalprocesseshas hadanimportantroletoplayinthedevelopmentoftechnologyoverthe centuriesandparticularlysointhelastonehundredand?ftyyearsorso.

Itcanbearguedthatitismoreimportanttodaythaneverbeforesincethe availabilityofhigh-speedcomputersallowsaccuratenumericalsimulationof industrialprocessesatafractionofthecostofthecorrespondingexperiments.

Thisisoneaspectofmathematicalmodelling,highpro?leandmuchvalued, butitisnottheonlyone.

Inthepastmathematicalmodellinghadtorelyonqualitativeinves- gation,veryspecialanalyticalsolutions,orinaccurateandtime-consuming calculationsperformedwithlittleinthewayoftabulatedormechanical assistance. Logtablesandsliderulesarestillrememberedbypeopleworking today,thoughtherearesurelyfewwhoregrettheirdisappearance.

Thevalueanddistinctivefunctionofmethodsbasedontheanalytical approachisnowbecomingmuchclearer,nowthattheyarenolongerexpected toproducedetailedimitationsofwhathappensinrealexperimentsofind- trialprocesses,afunctionnowful?lledmostlybynumericalmethods,c- sideredbelow.

Theemphasistodayisontheirabilitytocon?rmandextend ourunderstandingofthebasicphysicalmechanismsinvolvedintheprocesses of interest.

These are essential for any intelligent use of numerical simulation.

Theargumentaboutthevalueofteachingpeoplehowtodoarithmetic themselveswithouttheaidofacalculatorseemstobepassingintohistory, vi Preface butitisanimportantoneandprovidesasimpleanalogy.

Ifsomeonedoes nothaveafeelingfornumbersandthewayarithmeticworks,theywillalltoo easilyfailtospotanerrorproducedbyamachine.

Computersarenotinfallible -andneitherarethosewhobuildorprogramthem.

Computersarenow takingonlessmundanemathematicaltasksandthesamecontroversiesare appearinginconnectionwithalgebraicmanipulation. Equally,andwitheven greaterpenaltiesintermsofcostintheeventoferrors,thesameconsiderations applytonumericalsimulationofmajorindustrialprocesses.

Awarenessofthe analyticalsolutionscanbeinvaluableindistinguishingtherightfromthe wrong,i. e. forthepractitionertounderstandthebasisofthework,andto haveanideaofthekindsofoutcomesthatareplausible-andtorecognise thosewhicharenot.

Thephrase"mathematicalmodelling"is,however,ambiguous,perhaps morenowthanithaseverbeen.

Thereisanenormousamountofworkdone todayonsimulationbasedontheuseofverypowerfulcomputerprograms, anditisquitecorrectlyreferredtoasmathematicalmodelling.

Theprograms aresometimesconstructedin-housebutareusuallycommercialpackages.

This isanentirelyvalidapproachwithspeci?c(generallycommercial)objectives.

Ingeneraltherearetwouses. Thedominantobjectiveisnumericalagreement withaparticularexperimentinthe?rstinstance,leadingtopredictivec- mercialuseinthesecondinstance.

Thesecondobjectiveistheclari?cation ofphysicalmechanisms,aimedatthegenerationofunderstandingofcomplex interconnectedprocesses,ratherthantheexactreproductionofaparticular experiment.

Itissometimesoverlookedthat,withsu?cientcare,anum- icalapproachisequallyvalidintheinvestigationofphysicalfundamentals. Numericalsimulationisnotacentraltopicofthisbook,butbecauseofits crucialimportancetoeachofthetwousestowhichnumericalmodellingcan beput,itisvitalthatthecomputationalbasisoftheworkshouldbec- pletelysound.

Inaddition,thelevelofprocessdetailwhichcanbeconsidered bythenumericalapproachusuallyexceedswhatispossiblewiththeanaly- calapproachsigni?cantly,leavinglittlechoicebuttoreverttothenumerical treatmentwheninvestigatingtheinterconnectionsbetweenprocesses.

Itis forthesereasonsthatthebookconcludeswithachapteroncomprehensive numericalsimulation.

Inmanyways,theapproachadoptedhereiscomplementarytothemore phenomenologicalapproach.

Itisalwaysimportantina?eldwhichhasvery directindustrialapplicationstobearinmindhowtechniquessuchasthose describedherewillbeused,butitisessentialnottolosesightofthef- damentals.

Thereareserioussafetyimplications;therearecostimplications; therearemoralimplications;thereareconsiderationsoftheappropriateness ofthetechnologytotheapplicationunderconsideration.

Aproperrespectfor alltheserequiresanunderstandingofthefundamentals.

Wearealltoowellawarethatthisbookdoeslittlemorethanscratch thesurfaceoftheproblemsinvolvedinafundamentalunderstandingofthese phenomena. Ifwehaveprovidedideasandinformationthatcauseothersto Preface vii testthemexperimentallyorintellectually,agreewiththemordisputethem vigorously,anddevelopthemfurther,wewillconsiderthatwehaveachieved ouraim.

Colchester April,2008 JohnDowden Contents 1MathematicsinLaserProcessing JohnDowden...1 1. 1 MathematicsanditsApplication...1 1. 2 FormulationinTermsofPartialDi?erentialEquations...3 1. 2. 1 LengthScales...3 1. 2. 2 ConservationEquationsandtheirGeneralisations...4 1. 2. 3 GoverningEquationsofGeneralised ConservationType...7 1. 2. 4 Gauss'sLaw...10 1. 3 BoundaryandInterfaceConditions...11 1. 3. 1 GeneralisedConservationConditions...11 1. 3. 2 TheKinematicConditioninFluidDynamics...13 1. 4 Fick'sLaws...15 1. 5 Electromagnetism...15 1. 5. 1 Maxwell'sEquations...15 1. 5. 2 Ohm'sLaw...18 References...19 2SimulationofLaserCutting WolfgangSchulz,MarkusNiessen,UrsEppelt,KerstinKowalick...21 2. 1 Introduction...22 2. 1. 1 PhysicalPhenomenaandExperimentalObservation...23 2. 2 MathematicalFormulationandAnalysis...26 2. 2. 1 TheOne-PhaseProblem...29 2. 2. 2 TheTwo-PhaseProblem...42 2. 2. 3 Three-PhaseProblem...51 2. 3 Outlook...64 2. 4 Acknowledgements...65 References...65 x Contents 3KeyholeWelding:TheSolidandLiquidPhases AlexanderKaplan...71 3. 1 HeatGenerationandHeatTransfer...71 3. 1. 1 Absorption...