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<p>The laser weld quality significantly correlates with characteristics of the molten pool forming during the process. This paper aims at understanding and predicting the molten pool characteristics in the EN24 steel, a&#xa0;high-strength alloy widely used in demanding applications. The applied dual approach includes&#xa0;(1) the numerical simulation in COMSOL Multiphysics for the heat transfer and the molten pool behavior and&#xa0;(2) a&#xa0;series of welding experiments with the EN24 steel. A&#xa0;Taguchi L9 orthogonal array design is used in the experiments, systematically varying two key factors, namely the laser power (1500, 1650, 1800 W) and scanning speed (10, 14, 18 mm/s), each at three distinct levels. The numerical simulation focused on the heat transfer in solids, offers information about how these parameters affect the molten pool width, depth, and overall shape. Experimental validation based on the metallographic analysis of weld cross-sections, verifies modeling patterns. This integrated approach not only validates the predictive power, but also provides a&#xa0;better understanding of the complex relationship between welding parameters and the molten pool morphology in the EN24 steel, giving a&#xa0;way for more efficient process optimization and the higher weld quality.</p>

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Parametric simulation and experimental analysis of molten pool characteristics of EN24 steel during laser beam welding

  • 期刊论文

  • 发表日期：

    2025年11月1日

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  • Piyush Rai,
  • Pradeep Kumar,
  • Mohd Zaheer Khan Yusufzai,
  • Meghanshu Vashista

摘要

The laser weld quality significantly correlates with characteristics of the molten pool forming during the process. This paper aims at understanding and predicting the molten pool characteristics in the EN24 steel, a high-strength alloy widely used in demanding applications. The applied dual approach includes (1) the numerical simulation in COMSOL Multiphysics for the heat transfer and the molten pool behavior and (2) a series of welding experiments with the EN24 steel. A Taguchi L9 orthogonal array design is used in the experiments, systematically varying two key factors, namely the laser power (1500, 1650, 1800 W) and scanning speed (10, 14, 18 mm/s), each at three distinct levels. The numerical simulation focused on the heat transfer in solids, offers information about how these parameters affect the molten pool width, depth, and overall shape. Experimental validation based on the metallographic analysis of weld cross-sections, verifies modeling patterns. This integrated approach not only validates the predictive power, but also provides a better understanding of the complex relationship between welding parameters and the molten pool morphology in the EN24 steel, giving a way for more efficient process optimization and the higher weld quality.