During hybrid laser-arc welding of galvanized dual phase steel 980 in a gap free lap joint configuration, the welding parameters have the significant influences on the weld quality, which is directly related to the temperature distribution of welds. In this paper, a 3D FEM model is used with the application of the double ellipsoidal moving heat source to simulate the transient temperature field and the dimensions of fusion zone and heat affected zone (HAZ) for hybrid laser-arc keyhole welding of galvanized steels in a gap-free lap joint configuration. Temperature-dependent thermophysical properties are used in the simulation. Effects of various welding parameters on the temperature distribution are studied. To validate the numerical results, a high-speed camera with the frame rate of 4000 fps is used to real-time capture the images of the molten pool. The numerical results show a good agreement with the experimental results.

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