A multi-regime thermal source model for laser welding process optimization

Industrial laser welding requires rapid parameter optimization, but existing CFD models remain too computationally expensive for practical use. This work addresses this challenge through a calibrated multi-regime thermal source model that enables fast prediction of weld geometry while maintaining engineering accuracy. The model uniquely combines conduction and keyhole welding regimes within a single analytical framework, accounting for beam wobbling and plasma effects. Validated through bead-on-plate experiments on IN625 across industrial-relevant parameters, the approach reduces computational effort significantly compared to fluid dynamics simulations, making it suitable for industrial parameter screening and optimization.