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<p>This study presents a combined finite element simulation and experimental investigation on CO<sub>2</sub> laser welding of Hastelloy X, focusing on the influence of key process parameters—laser power (3-3.4&#xa0;kW), welding speed (0.6-1&#xa0;m/min), and focal length (198-202&#xa0;mm). An L9 orthogonal array was adopted for systematic experimentation. A three-dimensional transient finite element model employing a Gaussian moving heat source was developed using ANSYS analysis software to predict temperature distribution and peak fusion zone temperatures, ensuring weldability. Numerical results revealed steep thermal gradients and peak temperatures up to ~ 3100&#xa0;K at higher power and lower welding speeds, confirming a strong correlation between heat input and residual stress development. Microstructural analysis showed refined dendritic structures in the fusion zone with a narrow heat-affected zone. Mechanical testing indicated an inverse relationship between grain size and tensile strength, with a maximum strength of 684&#xa0;MPa (EX 5) and a minimum of 540&#xa0;MPa (EX 8), while peak microhardness was observed in EX 4. Laser power and welding speed were identified as dominant factors governing weld quality and performance. Optimal joint integrity was achieved at 3.4&#xa0;kW laser power and 0.8&#xa0;m/min welding speed, demonstrating the effectiveness of coupled FEA–experimental approaches for process optimization. </p>

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Finite Element Thermal Simulation and Experimental Study of Laser Beam Welded Hastelloy X Joints

  • 期刊论文

  • 发表日期：

    2026年3月23日

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  • G. Sathishkumar,
  • Harinadh Vemanaboina,
  • S. Senthil Murugan,
  • P. Sathiya,
  • G. Sathyamoorthy

摘要

This study presents a combined finite element simulation and experimental investigation on CO2 laser welding of Hastelloy X, focusing on the influence of key process parameters—laser power (3-3.4 kW), welding speed (0.6-1 m/min), and focal length (198-202 mm). An L9 orthogonal array was adopted for systematic experimentation. A three-dimensional transient finite element model employing a Gaussian moving heat source was developed using ANSYS analysis software to predict temperature distribution and peak fusion zone temperatures, ensuring weldability. Numerical results revealed steep thermal gradients and peak temperatures up to ~ 3100 K at higher power and lower welding speeds, confirming a strong correlation between heat input and residual stress development. Microstructural analysis showed refined dendritic structures in the fusion zone with a narrow heat-affected zone. Mechanical testing indicated an inverse relationship between grain size and tensile strength, with a maximum strength of 684 MPa (EX 5) and a minimum of 540 MPa (EX 8), while peak microhardness was observed in EX 4. Laser power and welding speed were identified as dominant factors governing weld quality and performance. Optimal joint integrity was achieved at 3.4 kW laser power and 0.8 m/min welding speed, demonstrating the effectiveness of coupled FEA–experimental approaches for process optimization.