Numerical simulation on the laser beam welded UNS S32304 duplex steel and 304L stainless steel joints using ANSYS and response surface methodology

Duplex Stainless Steel, known for its corrosion resistance and strength, is extensively utilized in industrial applications. However, it faces challenges under variable loading conditions, including impact loading and specific temperature scenarios. Traditional welding methods exacerbate these concerns. This study proposes a numerical simulation for the combination of UNS S32304 and SS304L, employing the Laser Beam Welding technique to enhance the ductility of the structure, particularly under critical conditions. The structural performance is evaluated based on Total Deformation (TD), Maximum Principal Stress (MPS), and shear stress. Utilizing the Response Surface Methodology, various parameters are statistically tested and optimized to ensure superior outcomes. ANSYS software is employed, considering different clearance gaps between UNS S32304 and SS304L joints while varying beam diameter, Heat Affected Zone Temperature (HAZT), and force. Results indicate that the applied force is a primary factor contributing to stress in the structural experimentation of UNS S32304 and SS304L joints. The analysis exhibits a sufficient fit, significant signal-to-noise ratio, and desirable results as confirmed by the Analysis of Variance and fit statistics. Optimized parameters for the task include Bead Width Clearance (BWC) of 1.00687 mm, beam diameter of 1.00469 mm, HAZT of 1500.41 °C, and force of 6482.06 kN, demonstrating superior results compared to current field standards. Perturbation analysis for TD, MPS, and shear stress is further explored for various factor levels, providing comprehensive insights into the structural behavior under different conditions. This research establishes that the combination of UNS S32304 and SS304L dissimilar joints is robust enough to withstand high-loading conditions, offering valuable contributions to the field of material engineering.