Simulation of deformation in laser joining of typical components of carbon fiber reinforced composite and 6061 aluminum alloy

Objective This study aims to investigate deformation laws of typical components made of carbon fiber reinforced composite and 6061 aluminum alloy during laser joining. Methods Taking lightweight equipment compartment end plate of a new high-speed train as the research object for deformation analysis of dissimilar material components during laser joining, a combined numerical simulation and experimental approach was adopted. Firstly, a combined heat source model was established, and its rationality for simulating temperature field of dissimilar material components was verified. Subsequently, thermal cycle curve method was employed to simulate deformation of aluminum alloy stiffeners and carbon fiber reinforced thermoplastic composite substrates during laser joining, and influences of welding sequence, constraint conditions and laser power on welding deformation of dissimilar material components were analyzed. Results By comparing the simulated deformation results with the experimental ones of dissimilar material components after joining, it was found that deformation trends were basically consistent. Conclusion The maximum deformation of dissimilar material components always occurs at the central position. Welding sequence has no significant effect on the final deformation of the components. Z-direction constraint can significantly reduce the overall deformation of the components, and the post-joining deformation of dissimilar material components increases overall with the increase of laser power.