Identification of parametric conditions and the influence of laser interaction on the material removal and surface characteristics of 904 L steel super austenitic stainless steel

Fiber laser machining has emerged as a versatile and efficient method for processing an extensive variety of materials, including high-alloy steels like 904 L. The purpose of this research is to optimize fiber laser cutting parameters for 904 L alloy to improve surface quality and machining efficiency. Central composite design (CCD) was used to explore the machining characteristics of fiber laser machined 904 L by varying cutting speed, laser power, nozzle distance and frequency. With increases in power (P), cutting speed (C_S), and frequency (F), the material removal rate (MRR) of 904 L alloy was enhanced by 76.99%. The surface quality was improved by 74.45% with a decrease in cutting speed (C_S), laser power (P), and an increase in frequency (F) and nozzle distance (N_D).The surface hardness of machined 904 L was increased because of the deposition of molten metal on the machined region. However, the hardness can be controlled by considering optimal cutting speed and laser power. This leads to less deposition of resolidification layer on the cut surface. Surface topography investigation revealed the presence of debris, and melt flow caused by nitrogen gas flow affected the surface roughness. The study aims to identify the optimal machining parameters for higher material removal with good quality surface, and minimize the surface defects. The results of this research will not only contribute to the fiber laser cutting for 904 L steel but also offer valuable insights into optimizing the cutting processes for other high-alloy steels, ultimately enhancing manufacturing efficiency in various industrial applications.