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<p>Dissimilar laser beam Welding (LBW) of Duplex (UNS S32304) and Austenitic (SS304L) stainless steels involves complex thermal behavior and phase transformations, which usually lead to decreased weld quality and mechanical properties. Previous research has mainly dealt with homogeneous joints, with few optimization strategies for dissimilar stainless-steel combinations. This research addresses this specific gap by maximizing key LBW parameters laser power, welding speed, and focal position to maximize weld strength and structural integrity in dissimilar joints. 27 samples of experiments were investigated to assess the impact of input parameters on output characteristics such as bead width and Ultimate Tensile Strength (UTS). Focal length was determined to be a significant factor, with UTS at its peak of 500&#xa0;MPa at 0&#xa0;mm and declining to 200&#xa0;MPa at 4&#xa0;mm, indicating a high negative correlation. Conversely, laser power variation had little effect in the range tested. Higher welding speed was also discovered by the research to increase microhardness and tensile strength and reduce defect rates and response surface methodology used for the predictive analysis. The findings offer a more accurate parameter window for the achievement of high-performance dissimilar joints and validate the use of predictive modeling in novel welding processes.</p>

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Process Optimization and Correlation Analysis for Laser Beam Welded UNS S32304/SS304L

  • 期刊论文

  • 发表日期：

    2026年1月20日

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  • Chodagam Lakshmi Poornima,
  • Chalamalasetty Srinivasa Rao

摘要

Dissimilar laser beam Welding (LBW) of Duplex (UNS S32304) and Austenitic (SS304L) stainless steels involves complex thermal behavior and phase transformations, which usually lead to decreased weld quality and mechanical properties. Previous research has mainly dealt with homogeneous joints, with few optimization strategies for dissimilar stainless-steel combinations. This research addresses this specific gap by maximizing key LBW parameters laser power, welding speed, and focal position to maximize weld strength and structural integrity in dissimilar joints. 27 samples of experiments were investigated to assess the impact of input parameters on output characteristics such as bead width and Ultimate Tensile Strength (UTS). Focal length was determined to be a significant factor, with UTS at its peak of 500 MPa at 0 mm and declining to 200 MPa at 4 mm, indicating a high negative correlation. Conversely, laser power variation had little effect in the range tested. Higher welding speed was also discovered by the research to increase microhardness and tensile strength and reduce defect rates and response surface methodology used for the predictive analysis. The findings offer a more accurate parameter window for the achievement of high-performance dissimilar joints and validate the use of predictive modeling in novel welding processes.