Investigation on the mechanism of a new laser surface structuring by laser remelting

A new method of surface structuring by laser remelting with the help of surface tension (mainly thermocapillary force and solutocapillary force) and volume expansion was proposed. A multiphysics coupled numerical model was proposed for this surface structuring method, in which the calculation of surface tension and solutocapillary force is improved. Using the established numerical model, the formation mechanism of the surface structure was explored from the aspects of surface tension, fluid flow, volume expansion, and surface profile evolution. The reason why the surface structure changes from a “W” shape to an “A” shape was explained, and the contributions of thermocapillary force, solutocapillary force, and volume expansion to the surface structure were investigated. The effects of laser power, scanning speed, and beam diameter on the surface profile of the surface structure were studied by experiments, which indicates that the desired surface structure can be obtained by adjusting the process parameters. All the experimental results were simulated by the established numerical model, and the simulation results are in good agreement with the experimental results, indicating that the numerical model is effective and available.