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<p>Laser surface melting (LSM) is an advanced surface engineering technique used to enhance the mechanical and tribological properties of engineering materials. This study examined AISI 4340 steel, a prevalent high-strength low-alloy steel, subjected to LSM using a 4&#xa0;kW diode LDF 4000-30 laser operating in continuous-wave mode with six axes and a wavelength of 1080&#xa0;nm to analyze the effects of critical processing parameters—laser power, scanning speed, and focal distance on surface hardness and residual stress. The experiments utilized a Box–Behnken design of experiments (DOE) to systematically investigate parameter interactions and optimize process conditions. An empirical model was created to forecast output responses based on input parameter configurations. The desirability approach for optimization identified optimal parameter combinations that attained the requisite surface depth, hardness, and compressive residual stress, rendering the method exceptionally appropriate for precision surface engineering of AISI 4340 steel. The study revealed that scan speed significantly affected depth and hardness, while laser power induced residual stress. The multi-objective optimization employing the desirability function approach yielded an optimal parameter combination of laser power (L) = 1250&#xa0;W, scan speed (V) = – 2&#xa0;mm/s, and focal distance (F) = 320&#xa0;mm, maximizing depth, hardness, and residual stress, with a desirability function value of 0.82229. This work provides a novel, systematic methodology for optimizing LSM process parameters, offering insights into precision enhancement of high-strength steels for advanced engineering applications.</p>

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Laser Surface Engineering of AISI 4340 Steel: Process Optimization for Enhanced Mechanical Performance

  • 期刊论文

  • 发表日期：

    2025年11月13日

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  • G. Muthukumaran,
  • B. Rishi Kumar,
  • P. S. Sivasakthivel

摘要

Laser surface melting (LSM) is an advanced surface engineering technique used to enhance the mechanical and tribological properties of engineering materials. This study examined AISI 4340 steel, a prevalent high-strength low-alloy steel, subjected to LSM using a 4 kW diode LDF 4000-30 laser operating in continuous-wave mode with six axes and a wavelength of 1080 nm to analyze the effects of critical processing parameters—laser power, scanning speed, and focal distance on surface hardness and residual stress. The experiments utilized a Box–Behnken design of experiments (DOE) to systematically investigate parameter interactions and optimize process conditions. An empirical model was created to forecast output responses based on input parameter configurations. The desirability approach for optimization identified optimal parameter combinations that attained the requisite surface depth, hardness, and compressive residual stress, rendering the method exceptionally appropriate for precision surface engineering of AISI 4340 steel. The study revealed that scan speed significantly affected depth and hardness, while laser power induced residual stress. The multi-objective optimization employing the desirability function approach yielded an optimal parameter combination of laser power (L) = 1250 W, scan speed (V) = – 2 mm/s, and focal distance (F) = 320 mm, maximizing depth, hardness, and residual stress, with a desirability function value of 0.82229. This work provides a novel, systematic methodology for optimizing LSM process parameters, offering insights into precision enhancement of high-strength steels for advanced engineering applications.