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<p>High Power Diode Laser Beam Welding (HPDLBW) is a popular method for combining austenitic stainless steels because it has great electrical efficiency, precise heat input control, and stable conduction-mode welding. Welding AISI 304 (SS304) remains difficult because of porosity, hot cracking, residual stresses, and heat-affected zone (HAZ) sensitization. This work uses Taguchi design of experiments and analysis of variance (ANOVA) to evaluate the effect of HPDLBW process parameters on weld shape, microstructure, and mechanical performance, as well as to construct optimum processing-properties connections. Butt joints of 1.5&#xa0;mm thick SS304 sheets were welded using variable laser power (1500–2000&#xa0;W), welding speed (3–5&#xa0;m·min⁻¹), and beam diameter (0.2–0.4&#xa0;mm). Results demonstrate that raising laser power and reducing welding speed increased penetration depth by up to ~ 45%. Intermediate conditions generated defect-free welds with balanced bead geometry. The optimal parameter configuration (2000&#xa0;W, 4&#xa0;m·min⁻¹, 0.3&#xa0;mm) resulted in a maximum tensile strength of 657.4&#xa0;N·mm⁻², representing a ~ 58% improvement over the lowest-strength condition, with fracture occurring in the parent material. Microhardness rose by approximately 21% in the HAZ and 18% in the weld metal relative to the base metal due to grain refinement and reduced δ-ferrite production. Impact hardness remained constant (104–111&#xa0;J) under all situations. ANOVA revealed that laser power was the most important factor (48–60% contribution), followed by welding speed, with beam diameter having only a modest effect. These findings show that optimized HPDLBW may produce high-integrity SS304 joints appropriate for structural and precision manufacturing applications.</p>

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High Power Diode Laser Beam Welding of SS304 Stainless Steel: Influence of Process Parameters on Weld Quality and Mechanical Performance

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年1月16日

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  • Rajesh Patil,
  • Magnus Löfstrand

摘要

High Power Diode Laser Beam Welding (HPDLBW) is a popular method for combining austenitic stainless steels because it has great electrical efficiency, precise heat input control, and stable conduction-mode welding. Welding AISI 304 (SS304) remains difficult because of porosity, hot cracking, residual stresses, and heat-affected zone (HAZ) sensitization. This work uses Taguchi design of experiments and analysis of variance (ANOVA) to evaluate the effect of HPDLBW process parameters on weld shape, microstructure, and mechanical performance, as well as to construct optimum processing-properties connections. Butt joints of 1.5 mm thick SS304 sheets were welded using variable laser power (1500–2000 W), welding speed (3–5 m·min⁻¹), and beam diameter (0.2–0.4 mm). Results demonstrate that raising laser power and reducing welding speed increased penetration depth by up to ~ 45%. Intermediate conditions generated defect-free welds with balanced bead geometry. The optimal parameter configuration (2000 W, 4 m·min⁻¹, 0.3 mm) resulted in a maximum tensile strength of 657.4 N·mm⁻², representing a ~ 58% improvement over the lowest-strength condition, with fracture occurring in the parent material. Microhardness rose by approximately 21% in the HAZ and 18% in the weld metal relative to the base metal due to grain refinement and reduced δ-ferrite production. Impact hardness remained constant (104–111 J) under all situations. ANOVA revealed that laser power was the most important factor (48–60% contribution), followed by welding speed, with beam diameter having only a modest effect. These findings show that optimized HPDLBW may produce high-integrity SS304 joints appropriate for structural and precision manufacturing applications.