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<p>The welding of stainless steel and nickel-based alloys is significant for applications that demand simultaneous corrosion resistance and high-temperature performance. In the present research, 6-mm-thick plates of AISI 304 stainless steel and Inconel 625 were joined using a double-sided fiber laser welding process, resulting in defect-free butt welds. Nine dissimilar butt joint welds were fabricated by varying laser power, wobble frequency, wobble length, and welding speed while maintaining consistent shielding parameters and torch angle. A partially melted zone was identified adjacent to the Inconel 625 side and an unmixed zone on the AISI 304 side. The weld top is fine equiaxed; mid-depth shows equiaxed/cellular dendrites; and the root reveals columnar growth. EDS quantification evidenced a progressive compositional transition across the interface, consistent with interdendritic segregation, carbide, and laves-type precipitation. Tensile testing reveals the strongest joints in the 900 W group, characterized by ductile cup-and-cone failure in the AISI 304 heat-affected zone; intermediate strengths in the 1150 W group; and the lowest UTS at 1400 W. Higher powers reduce UTS and promote brittle weld-zone features. Vickers hardness measurements across the weld cross section showed a strong correlation with laser power input: Samples welded at 900 W exhibited the highest weld-zone hardness, while intermediate-power (1150 W) welds showed moderately reduced hardness. The lowest hardness was observed in samples welded at 1400 W. The Inconel side exhibited a higher mean hardness of approximately 502 HV, compared to the stainless steel side, which had a mean hardness of approximately 246 HV. The combined microstructural, compositional, and mechanical analyses show that low to moderate laser heat input promotes refined solidification behavior, limited elemental segregation, and improved strength. The observations confirm that double-sided fiber laser welding is a robust, economical method for making dissimilar-materials joints, suitable for the chemical, power generation, and marine industries.</p>

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Microstructural and Mechanical Characterization of Double-Sided Fiber Laser-Fabricated Butt Joints Between AISI 304 Stainless Steel and Inconel 625

  • 期刊论文

  • 发表日期：

    2026年3月31日

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  • Notan Kumar,
  • Aditya Kumar,
  • P. K. Bajpai,
  • Manoj Kumar Sinha

摘要

The welding of stainless steel and nickel-based alloys is significant for applications that demand simultaneous corrosion resistance and high-temperature performance. In the present research, 6-mm-thick plates of AISI 304 stainless steel and Inconel 625 were joined using a double-sided fiber laser welding process, resulting in defect-free butt welds. Nine dissimilar butt joint welds were fabricated by varying laser power, wobble frequency, wobble length, and welding speed while maintaining consistent shielding parameters and torch angle. A partially melted zone was identified adjacent to the Inconel 625 side and an unmixed zone on the AISI 304 side. The weld top is fine equiaxed; mid-depth shows equiaxed/cellular dendrites; and the root reveals columnar growth. EDS quantification evidenced a progressive compositional transition across the interface, consistent with interdendritic segregation, carbide, and laves-type precipitation. Tensile testing reveals the strongest joints in the 900 W group, characterized by ductile cup-and-cone failure in the AISI 304 heat-affected zone; intermediate strengths in the 1150 W group; and the lowest UTS at 1400 W. Higher powers reduce UTS and promote brittle weld-zone features. Vickers hardness measurements across the weld cross section showed a strong correlation with laser power input: Samples welded at 900 W exhibited the highest weld-zone hardness, while intermediate-power (1150 W) welds showed moderately reduced hardness. The lowest hardness was observed in samples welded at 1400 W. The Inconel side exhibited a higher mean hardness of approximately 502 HV, compared to the stainless steel side, which had a mean hardness of approximately 246 HV. The combined microstructural, compositional, and mechanical analyses show that low to moderate laser heat input promotes refined solidification behavior, limited elemental segregation, and improved strength. The observations confirm that double-sided fiber laser welding is a robust, economical method for making dissimilar-materials joints, suitable for the chemical, power generation, and marine industries.