Simplified numerical modeling with experimental validation of molten pool geometry in laser welding

Laser welding is widely adopted for its high speed, precision, and automation capabilities, delivering superior microstructural properties in material joining. However, suboptimal welding parameters can cause defects, necessitating accurate and computationally efficient simulation models. This study introduces a novel simplified numerical model for laser welding that optimizes the prediction of molten pool geometry while minimizing computational cost. By integrating a phase-change model with a calibrated Gaussian heat source, the approach balances accuracy and efficiency, addressing the limitations of complex fluid dynamics models and oversimplified temperature-based simulations. The model was validated against seven experimental cases involving Ti6Al4V and stainless steel 316 L, achieving zero error in melt pool depth prediction and maximum errors in top and bottom widths of <0.2 mm. This computationally efficient model enables rapid parameter optimization, making it ideal for large-scale industrial applications, including residual stress and distortion analysis. By offering a practical alternative to high-cost simulations, this work advances laser welding simulation for precision manufacturing and supports broader adoption in industries such as automotive and railway.