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<p>NiTi shape memory alloy (SMA) wires are vital in critical applications like aerospace and medical industries, yet achieving reliable butt-welded joints without impairing function poses challenges. This research optimizes Nd:YAG laser welding to simultaneously enhance tensile strength and reduce corrosion rate, complemented by a sustainability assessment. A full-factorial experiment design (3 factors × 3 levels; 27 runs) tests the impacts of pulse width, frequency, and focal length. Variance analysis reveals that focal length accounts for 74.77% of TS variation, while frequency influences 82.56% of CR variation. To address the trade-off between responses, a hybrid Grey Relational Analysis–Whale Optimization Algorithm (GRA-WOA) is utilized. Compared to standalone GRA, GRA-WOA achieves a 9.05% increase in TS (320.68&#xa0;MPa) and a 73.34% decrease in CR (0.0017&#xa0;mm/year), offering a balanced performance improvement. Microstructural analysis (SEM/EDS) at the optimized parameters shows fewer welding defects and more uniform elemental distribution, aligning with the observed mechanical and corrosion improvements. A Pugh matrix sustainability evaluation indicates Nd:YAG welding surpasses conventional and CO₂ laser methods, particularly in terms of energy efficiency, recyclability, and lifecycle costs. This research combines detailed experimentation, metaheuristic multi-objective optimization, and multi-criteria decision-making to deliver a validated, user-ready framework for high-quality, sustainable NiTi SMA wire welding.</p>

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Optimizing nickel-titanium wire laser butt joints: strength, corrosion trade‑off and sustainability benchmark

  • 期刊论文

  • 发表日期：

    2026年1月6日

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  • Soumya Ranjan Parimanik,
  • Debadutta Mishra,
  • Trupti Ranjan Mahapatra

摘要

NiTi shape memory alloy (SMA) wires are vital in critical applications like aerospace and medical industries, yet achieving reliable butt-welded joints without impairing function poses challenges. This research optimizes Nd:YAG laser welding to simultaneously enhance tensile strength and reduce corrosion rate, complemented by a sustainability assessment. A full-factorial experiment design (3 factors × 3 levels; 27 runs) tests the impacts of pulse width, frequency, and focal length. Variance analysis reveals that focal length accounts for 74.77% of TS variation, while frequency influences 82.56% of CR variation. To address the trade-off between responses, a hybrid Grey Relational Analysis–Whale Optimization Algorithm (GRA-WOA) is utilized. Compared to standalone GRA, GRA-WOA achieves a 9.05% increase in TS (320.68 MPa) and a 73.34% decrease in CR (0.0017 mm/year), offering a balanced performance improvement. Microstructural analysis (SEM/EDS) at the optimized parameters shows fewer welding defects and more uniform elemental distribution, aligning with the observed mechanical and corrosion improvements. A Pugh matrix sustainability evaluation indicates Nd:YAG welding surpasses conventional and CO₂ laser methods, particularly in terms of energy efficiency, recyclability, and lifecycle costs. This research combines detailed experimentation, metaheuristic multi-objective optimization, and multi-criteria decision-making to deliver a validated, user-ready framework for high-quality, sustainable NiTi SMA wire welding.