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<p>This study systematically investigated the effects of laser power (300–700 W) and welding speed (3–5&#xa0;mm/s) on weld geometry and defect formation in laser butt welding of Haynes 282. Heat input was quantified using power density, interaction time, and energy density. Partial penetration occurred under all 300 W conditions and the 400 W–5&#xa0;mm/s condition, whereas full penetration was achieved in all other conditions. Based on the calculated power density and wide, shallow weld morphology, the investigated process window was interpreted as more consistent with conduction-dominated behavior than typical keyhole-mode welding. Both face and root widths increased with increasing laser power and decreasing welding speed. The increase in face width was attributed to enhanced outward Marangoni-driven surface flow, supported by a negative temperature coefficient of surface tension (<i>d</i>γ/<i>dT</i> &lt; 0) calculated from the actual Haynes 282 composition. Underfill and root reinforcement increased simultaneously due to the combined effects of recoil pressure and gravity. X-ray CT analysis revealed a complex, nonlinear pore distribution: the 400 W–5&#xa0;mm/s condition exhibited the highest pore count, whereas the 500 W–4&#xa0;mm/s condition showed the maximum porosity. These anomalous pore characteristics could be associated with transient weld pool instability arising from the localized imbalance between outward Marangoni flow and downward recoil-pressure-driven flow, supporting shielding gas entrapment prior to solidification. Considering both external geometry and internal integrity, the 500 W–5&#xa0;mm/s condition was identified as optimal within the investigated process window.</p>

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Influence of laser welding parameters on weld geometry and defect formation in Haynes 282 superalloy

  • 期刊论文

  • 发表日期：

    2026年7月12日

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  • Hee Pyeong Yang,
  • Deok Hyun Jo,
  • Gyu Heun Lee,
  • Sunmi Shin,
  • Byung Jun Kim,
  • Byoungkoo Kim,
  • Chang Woo Lee,
  • Jong Bae Jeon

摘要

This study systematically investigated the effects of laser power (300–700 W) and welding speed (3–5 mm/s) on weld geometry and defect formation in laser butt welding of Haynes 282. Heat input was quantified using power density, interaction time, and energy density. Partial penetration occurred under all 300 W conditions and the 400 W–5 mm/s condition, whereas full penetration was achieved in all other conditions. Based on the calculated power density and wide, shallow weld morphology, the investigated process window was interpreted as more consistent with conduction-dominated behavior than typical keyhole-mode welding. Both face and root widths increased with increasing laser power and decreasing welding speed. The increase in face width was attributed to enhanced outward Marangoni-driven surface flow, supported by a negative temperature coefficient of surface tension (dγ/dT < 0) calculated from the actual Haynes 282 composition. Underfill and root reinforcement increased simultaneously due to the combined effects of recoil pressure and gravity. X-ray CT analysis revealed a complex, nonlinear pore distribution: the 400 W–5 mm/s condition exhibited the highest pore count, whereas the 500 W–4 mm/s condition showed the maximum porosity. These anomalous pore characteristics could be associated with transient weld pool instability arising from the localized imbalance between outward Marangoni flow and downward recoil-pressure-driven flow, supporting shielding gas entrapment prior to solidification. Considering both external geometry and internal integrity, the 500 W–5 mm/s condition was identified as optimal within the investigated process window.