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<p>The nickel-based superalloy Incoloy 800 is widely used in high-temperature and corrosive environments, such as nuclear reactors and aerospace engines, owing to its excellent mechanical and chemical stability. While previous studies have typically focused on single-objective optimization using conventional or pulsed arc welding methods, limited work has explored multi-objective optimization of weld bead characteristics using fiber laser welding techniques. This study investigates the effect of key Ytterbium Fiber Laser Welding (Yb FLW) parameters—laser power, duty cycle, welding speed, and frequency—on the weld bead geometry of 2&#xa0;mm thick Incoloy 800 sheets. Using a Central Composite Design (CCD) of Response Surface Methodology (RSM), empirical models were developed to simultaneously predict bead width and depth of penetration with second-order accuracy. ANOVA confirmed the significance of the models, with a prediction error below 5%. The optimal parameter combination (power: 780&#xa0;W, duty cycle: 85%, speed: 850&#xa0;mm/min, frequency: 5000&#xa0;Hz) achieved a minimum bead width of 1.1&#xa0;mm and a full depth of penetration of 2.1&#xa0;mm. This paper discusses the effect of FLW parameters on tensile strength. The optimized value of the ultimate tensile strength of 515.19&#xa0;MPa, which is higher than that of the base metal. Additionally, a maximum microhardness of 184 HV was recorded in the weld zone, attributed to refined columnar dendrites under low heat input conditions. The weld zone exhibited high hardness across all experiments. The microstructure of the weld bead is studied using an Optical Microscope (OM) and scanning electron microscope (SEM). XRD analysis reveals the microstructural characteristics and elemental distribution in the weld zone. The developed models demonstrate high predictive accuracy and can effectively guide process parameter selection to achieve optimal weld quality in nickel-based alloys.</p>

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Optimisation of Weld Bead Geometry and Mechanical Characterisation on Fiber Laser Welded Similar Joints Using Nickel-Based Incoloy800

  • 期刊论文

  • 发表日期：

    2026年3月10日

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  • Seenivasan Sankarasubramanian,
  • Varahamoorthi Raju,
  • Saravanan Paramasivam,
  • Selvarajan Lakshmanan

摘要

The nickel-based superalloy Incoloy 800 is widely used in high-temperature and corrosive environments, such as nuclear reactors and aerospace engines, owing to its excellent mechanical and chemical stability. While previous studies have typically focused on single-objective optimization using conventional or pulsed arc welding methods, limited work has explored multi-objective optimization of weld bead characteristics using fiber laser welding techniques. This study investigates the effect of key Ytterbium Fiber Laser Welding (Yb FLW) parameters—laser power, duty cycle, welding speed, and frequency—on the weld bead geometry of 2 mm thick Incoloy 800 sheets. Using a Central Composite Design (CCD) of Response Surface Methodology (RSM), empirical models were developed to simultaneously predict bead width and depth of penetration with second-order accuracy. ANOVA confirmed the significance of the models, with a prediction error below 5%. The optimal parameter combination (power: 780 W, duty cycle: 85%, speed: 850 mm/min, frequency: 5000 Hz) achieved a minimum bead width of 1.1 mm and a full depth of penetration of 2.1 mm. This paper discusses the effect of FLW parameters on tensile strength. The optimized value of the ultimate tensile strength of 515.19 MPa, which is higher than that of the base metal. Additionally, a maximum microhardness of 184 HV was recorded in the weld zone, attributed to refined columnar dendrites under low heat input conditions. The weld zone exhibited high hardness across all experiments. The microstructure of the weld bead is studied using an Optical Microscope (OM) and scanning electron microscope (SEM). XRD analysis reveals the microstructural characteristics and elemental distribution in the weld zone. The developed models demonstrate high predictive accuracy and can effectively guide process parameter selection to achieve optimal weld quality in nickel-based alloys.