Optimization of Laser Welding Parameters and Fixed Stress Span Design to Minimize Deformation in Ultra-Thin Ferritic Stainless Steel
Ultra-thin ferritic stainless steel, essential for applications such as proton exchange membrane fuel cells, presents challenges during pulsed laser welding due to thermal stresses causing deformation. This study explores the effects of welding parameters and clamp design on deformation through fini...
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MDPI AG
2025-03-01
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| author | Jinlong Su Jingyi Li Kaining Zhu Fei Xing Xiaoming Qiu Jingwei Liang |
| author_facet | Jinlong Su Jingyi Li Kaining Zhu Fei Xing Xiaoming Qiu Jingwei Liang |
| author_sort | Jinlong Su |
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| description | Ultra-thin ferritic stainless steel, essential for applications such as proton exchange membrane fuel cells, presents challenges during pulsed laser welding due to thermal stresses causing deformation. This study explores the effects of welding parameters and clamp design on deformation through finite element simulations and experiments. Key parameters, including laser power (500–700 W), welding speed (6–14 mm/s), and pulse frequency (6–14 Hz), were systematically varied. Results revealed a non-linear relationship between these parameters and weld quality, with the optimal combination identified as a laser power of 600 W, welding speed of 10 mm/s, and pulse frequency of 10 Hz. Additionally, the fixed stress span applied by clamps significantly influenced stress–strain and displacement fields. For instance, residual stress decreased from 267 MPa at a 5 mm span to 189 MPa at a 20 mm span. Displacement values increased from 4.746 × 10⁻<sup>3</sup> mm at 5 mm to 8.111 × 10⁻<sup>3</sup> mm at 20 mm, while strain initially decreased but rose slightly from 1.648 × 10⁻<sup>3</sup> at 10 mm to 1.719 × 10⁻<sup>3</sup> at 15 mm. The 5 mm stress span was found optimal, producing a smooth and defect-free weld surface. This study bridges gaps in understanding the deformation mechanics of ultra-thin ferritic stainless steel, offering practical guidelines for optimizing laser welding parameters and clamp designs to achieve superior weld quality. |
| format | Article |
| id | doaj-art-c872ffcda93041d98c878596248eb652 |
| institution | DOAJ |
| issn | 2075-4701 |
| language | English |
| publishDate | 2025-03-01 |
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| spelling | doaj-art-c872ffcda93041d98c878596248eb6522025-08-20T02:42:26ZengMDPI AGMetals2075-47012025-03-0115332510.3390/met15030325Optimization of Laser Welding Parameters and Fixed Stress Span Design to Minimize Deformation in Ultra-Thin Ferritic Stainless SteelJinlong Su0Jingyi Li1Kaining Zhu2Fei Xing3Xiaoming Qiu4Jingwei Liang5Key Laboratory of Automobile Materials (Ministry of Education), School of Materials Science and Engineering, Jilin University, No. 5988 Renmin Street, Changchun 130022, ChinaKey Laboratory of Automobile Materials (Ministry of Education), School of Materials Science and Engineering, Jilin University, No. 5988 Renmin Street, Changchun 130022, ChinaState Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001, ChinaKey Laboratory of Automobile Materials (Ministry of Education), School of Materials Science and Engineering, Jilin University, No. 5988 Renmin Street, Changchun 130022, ChinaKey Laboratory of Automobile Materials (Ministry of Education), School of Materials Science and Engineering, Jilin University, No. 5988 Renmin Street, Changchun 130022, ChinaKey Laboratory of Automobile Materials (Ministry of Education), School of Materials Science and Engineering, Jilin University, No. 5988 Renmin Street, Changchun 130022, ChinaUltra-thin ferritic stainless steel, essential for applications such as proton exchange membrane fuel cells, presents challenges during pulsed laser welding due to thermal stresses causing deformation. This study explores the effects of welding parameters and clamp design on deformation through finite element simulations and experiments. Key parameters, including laser power (500–700 W), welding speed (6–14 mm/s), and pulse frequency (6–14 Hz), were systematically varied. Results revealed a non-linear relationship between these parameters and weld quality, with the optimal combination identified as a laser power of 600 W, welding speed of 10 mm/s, and pulse frequency of 10 Hz. Additionally, the fixed stress span applied by clamps significantly influenced stress–strain and displacement fields. For instance, residual stress decreased from 267 MPa at a 5 mm span to 189 MPa at a 20 mm span. Displacement values increased from 4.746 × 10⁻<sup>3</sup> mm at 5 mm to 8.111 × 10⁻<sup>3</sup> mm at 20 mm, while strain initially decreased but rose slightly from 1.648 × 10⁻<sup>3</sup> at 10 mm to 1.719 × 10⁻<sup>3</sup> at 15 mm. The 5 mm stress span was found optimal, producing a smooth and defect-free weld surface. This study bridges gaps in understanding the deformation mechanics of ultra-thin ferritic stainless steel, offering practical guidelines for optimizing laser welding parameters and clamp designs to achieve superior weld quality.https://www.mdpi.com/2075-4701/15/3/325ultra-thin stainless steelpulsed laser weldingdeformationtooling clamps |
| spellingShingle | Jinlong Su Jingyi Li Kaining Zhu Fei Xing Xiaoming Qiu Jingwei Liang Optimization of Laser Welding Parameters and Fixed Stress Span Design to Minimize Deformation in Ultra-Thin Ferritic Stainless Steel Metals ultra-thin stainless steel pulsed laser welding deformation tooling clamps |
| title | Optimization of Laser Welding Parameters and Fixed Stress Span Design to Minimize Deformation in Ultra-Thin Ferritic Stainless Steel |
| title_full | Optimization of Laser Welding Parameters and Fixed Stress Span Design to Minimize Deformation in Ultra-Thin Ferritic Stainless Steel |
| title_fullStr | Optimization of Laser Welding Parameters and Fixed Stress Span Design to Minimize Deformation in Ultra-Thin Ferritic Stainless Steel |
| title_full_unstemmed | Optimization of Laser Welding Parameters and Fixed Stress Span Design to Minimize Deformation in Ultra-Thin Ferritic Stainless Steel |
| title_short | Optimization of Laser Welding Parameters and Fixed Stress Span Design to Minimize Deformation in Ultra-Thin Ferritic Stainless Steel |
| title_sort | optimization of laser welding parameters and fixed stress span design to minimize deformation in ultra thin ferritic stainless steel |
| topic | ultra-thin stainless steel pulsed laser welding deformation tooling clamps |
| url | https://www.mdpi.com/2075-4701/15/3/325 |
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