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<p>This study aims to investigate and optimize process parameters of continuous fiber laser welding of 2&#xa0;mm thickness Al-Mg alloy (AA5754) sheets without the use of filler wire. The study focuses on evaluating and optimizing properties of fiber laser welded of thin AA5754 butt joints without filler wire. Moreover, high thermal conductivity and thermal expansion of AA5754 makes the welding of thin sheets more challenging. The welding experiments were performed using the Taguchi L9 design of experiments by varying input parameters at three different levels. Continuous fiber laser welding was used to weld the samples by changing laser power, welding speed, and wobble frequency. Response parameters including average heat affected zone (AHAZ), average weld bead width (AWW), and tensile strength were measured. Taguchi based analysis was carried out to determine the most influencing input factor while response surface regression analysis was used for predictive modelling. Obtained results suggest that sound welding quality may be obtained with good mechanical strength, and low porosity for a narrow set of welding parameters. Microstructural study revealed grain refinement in the fusion zone. The optimal parameter for butt joint of AA5754 (2&#xa0;mm) were determined for superior quality welds.</p>

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Mathematical Modelling and Process Optimization of Continuous Fiber Laser Welding of AA5754 Alloy Without Filler Wire

  • 期刊论文

  • 发表日期：

    2025年9月30日

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  • Gautam Singh,
  • Shashi Prakash

摘要

This study aims to investigate and optimize process parameters of continuous fiber laser welding of 2 mm thickness Al-Mg alloy (AA5754) sheets without the use of filler wire. The study focuses on evaluating and optimizing properties of fiber laser welded of thin AA5754 butt joints without filler wire. Moreover, high thermal conductivity and thermal expansion of AA5754 makes the welding of thin sheets more challenging. The welding experiments were performed using the Taguchi L9 design of experiments by varying input parameters at three different levels. Continuous fiber laser welding was used to weld the samples by changing laser power, welding speed, and wobble frequency. Response parameters including average heat affected zone (AHAZ), average weld bead width (AWW), and tensile strength were measured. Taguchi based analysis was carried out to determine the most influencing input factor while response surface regression analysis was used for predictive modelling. Obtained results suggest that sound welding quality may be obtained with good mechanical strength, and low porosity for a narrow set of welding parameters. Microstructural study revealed grain refinement in the fusion zone. The optimal parameter for butt joint of AA5754 (2 mm) were determined for superior quality welds.