Thermomechanical analysis applied to the laser beam welding simulation of aeronautical structures

Abstract
The present work is being done in the framework of a national program about the lightening of aeronautical structures and describes a three-dimensional finite element simulation of the laser beam welding process. The targeted aeronautical structures are stiffened panels in aluminum alloys, which tend to replace riveted assemblies. Semi-coupled thermomechanical finite element analyses have been carried out to evaluate the magnitude and distribution of welding-induced residual stresses in order to take them into account for fatigue sizing. The finite element code MSC.Marc is used for the different calculations. Specific welding features have been added to the code through the implementation of a moving heat source or an elastoviscoplastic law. Experimental tests have been carried out in order to provide mechanical and thermal databases to the model. Monitored experimental welding have been made for comparisons with the simulation. In particular, results of thermocouple measurements have permitted to improve the thermal model.