Beyond symmetry: Investigating asymmetric melt pool evolution in multi-pulse laser surface melting

A numerical investigation is carried out to explore the intricacies of multi-pulse pulsed laser surface melting (pLSM) to understand its impact on surface evolution. A finite-element-based multi-phase model with temperature-dependent properties is employed to track the interface for multiple laser pulses. Examining various overlap spacings and conducting a comparative analysis of the number of pulses, the study focuses on the exclusive influence of overlapping in surface texture generation. Notably, the assumption of an initially flat surface eliminates the effects of the initial surface roughness to provide unique insights completely based on multi-pulse dynamics. While the first pulse on a flat initial surface resulted in a symmetric surface evolution, asymmetric melt pools were observed in the second pulse and subsequent pulses. The asymmetry results from non-uniform cooling and melt pool flows influenced by the surface evolved in the first pulse. The topography-driven surface tension from the first pulse made the trailing peak solidify slower than the leading peak. The asymmetry was significant for smaller overlaps between the two pulses and reduced as the overlap increased. Further, an increase in the number of laser pulses promotes the generation of identical asymmetric surface features. In conclusion, the study demonstrates the importance of the developed model in accurately predicting the surface evolution influenced by topography-driven surface tension and that single pulse axisymmetric models are insufficient.