Laser Weld Aspect Optimization of Thin AISI 316 SS Using RSM in Relation with Welding Parameters and Sulfur Content

A quantitative and qualitative study of the effect of laser (light amplification by stimulated emissions of radiation) welding parameters, such as focus point, welding speed, power beam and shield gas on bead profile in relation with microchemistry compositions differences of two thin AISI 316 industrial stainless steel casts have been studied. One cast contains 60 ppm (0.006%) of sulfur considered as high sulfur content and the other one contains 10 ppm (0.001 %) sulfur which can be considered as low sulfur content. A set of 27 tests were carried out by combining three welding speeds (1500, 3000, and 4500 mm/min), three shield gases (helium (He), mixture of 40% helium and 60% argon (Ar) and mixture of 70% helium and 30% argon) with flow rate of 15 L/min, and three focal lengths (+2, +7, and +12 mm). The depth, aspect ratio (the ratio between the penetration depth weld and the weld width) and the bead cross section profile are investigated using response surface methodology (RSM). Linear and quadratic polynomial models for predicting the weld bead geometry were developed. The results of the preliminary validation indicated that the proposed models predict the responses adequately. The geometry of the welded area was analyzed using optical microscopy, and correlations between weld morphology (depth, weld aspect parameter and weld area) and welding parameters were performed. For the cast 316 HS (high sulfur content), the main input factor influencing the depth weld (Y-d) is the focus point with a contribution up to 19.32. On the other hand, the main input factor affecting the depth weld (Y-d) of the cast 316 LS (low sulfur content) is the combination effect of focus point and power input energy with contribution up to 10.65%. Sulfur as the surfactant element contributes to determining the laser weld bead shape up to 71% when the welds are partially penetrated and diminishes to 50% when the welds are fully penetrated with the occurrence of the keyhole mechanism.