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<p>The present work optimizes the laser beam welding process variables, such as beam offset, beam power, and welding speed, on responses such as ultimate tensile strength and microhardness of Ti6Al4V to AISI316L dissimilar joints using the solid-state fiber laser welding process with the RSM-GA hybrid optimization technique. This study uses a three-factor, three-level CCD (Central Composite Design) to minimize the number of tests for all parametric combinations. An empirical relationship is introduced to forecast the responses using welding parameters. The empirical model is optimized by using the genetic algorithm. It predicts optimal parameters as 4.99&#xa0;mm/s welding speed, 0.47&#xa0;mm beam offset, and 250-watt laser power to maximize responses. The confirmation test shows a nominal error percentage, which implies the accuracy of the proposed model. The sensitivity analysis shows laser power and beam offset are highly sensitive for ultimate tensile strength, whereas beam offset is highly sensitive for microhardness. The highest ultimate tensile strength (UTS) and average weld zone microhardness values achieved are 121&#xa0;MPa and 400 HV0.2, respectively.</p>

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Parametric Optimization of Autogenous Fiber Laser Welding Process for Ti6Al4V to AISI316L Joints

  • 期刊论文

  • 发表日期：

    2025年12月16日

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  • Amit Ratan Biswas,
  • Prosun Mandal,
  • Nitai Chandra Adak,
  • Nirvik Banerjee,
  • Saikat Ranjan Maity

摘要

The present work optimizes the laser beam welding process variables, such as beam offset, beam power, and welding speed, on responses such as ultimate tensile strength and microhardness of Ti6Al4V to AISI316L dissimilar joints using the solid-state fiber laser welding process with the RSM-GA hybrid optimization technique. This study uses a three-factor, three-level CCD (Central Composite Design) to minimize the number of tests for all parametric combinations. An empirical relationship is introduced to forecast the responses using welding parameters. The empirical model is optimized by using the genetic algorithm. It predicts optimal parameters as 4.99 mm/s welding speed, 0.47 mm beam offset, and 250-watt laser power to maximize responses. The confirmation test shows a nominal error percentage, which implies the accuracy of the proposed model. The sensitivity analysis shows laser power and beam offset are highly sensitive for ultimate tensile strength, whereas beam offset is highly sensitive for microhardness. The highest ultimate tensile strength (UTS) and average weld zone microhardness values achieved are 121 MPa and 400 HV0.2, respectively.