OPTIMIZATION OF LASER SPOT WELDING PARAMETERS FOR 304 STAINLESS STEEL THIN SHEETS USING NUMERICAL SIMULATION
Keywords:
numerical simulation, stainless steel, thin plate, laser spot welding, process optimization
Abstract
Laser spot welding of stainless steel is widely used for connecting vehicle body structures and electronic components. In this study, numerical simulation of laser spot welding was conducted on lap joints of 304 austenitic stainless steel thin plates measuring 120 × 80 × 0.8 mm. The equivalent stress and total deformation of the welded joints under different welding sequences and fixture clamping forces were investigated, and the stress and deformation around the weld spots were characterized. The results demonstrate that at a laser power of 1300 W, the equivalent stress after welding with the sequence (1-4-3-6-2-5) reaches a minimum value of the maximum equivalent stress of 421.87 MPa, indicating the optimal welding sequence. Under the optimal welding sequence, when the clamping forces on both sides are 100 N, the equivalent stress and total deformation reach the lowest values of 421.87 MPa and 0.27 mm, respectively, representing the optimal fixture clamping forces. These findings provide guidance for optimizing the laser spot welding process in industrial applications.
References
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20W. Zhou, Q. Le, Y. Shi, Q. Liao, Z. Yin, Y. Jiang, Numerical simulation of gas tungsten arc welding for ZW61 magnesium alloy thin plates, Mater Chem Phys, 329 (2025), 130130, https://doi.org/10.1016/j.matchemphys.2024.130130
21X. Fan, G. Qin, Z. Jiang, H. Wang, Comparative analysis between the laser beam welding and low current pulsed GMA assisted high-power laser welding by numerical simulation, J Mater Res Technol, 22 (2023), 2549-2565, https://doi.org/10.1016/j.jmrt.2022.12.116
22P. Xia, C. Wang, G. Mi, M. Zhang, L. Xiong, X. Zhang, C. Zhai, X. Feng, Y. Hu, Numerical simulation of molten pool flow behavior and keyhole evolution behavior in dual-laser beam oscillating bilateral synchronous welding of T-joints, Int J Heat Mass Transfer, 209 (2023), 124114, https://doi.org/10.1016/j.ijheatmasstransfer.2023.124114
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26H. Lebbal, M. Chaib, A. Slimane, D. Ait Kaci, N. Boualem, Experimental Investigation with Optimization of Spot Welding Parameters on Stainless Steel AISI 304, JOM, 75 (2023), 4993-5002, https://doi.org/10.1007/s11837-023-06136-3
27D. Rajesh, V. Chandran, N. Lenin, A. Subramanian, M. Deva, P. Balamurugan, Optimization of dual pulse resistance welding parameters for ASTM A240 stainless steel sheets: a multi-objective approach, Interactions, 245 (2024), 140, https://doi.org/10.1007/s10751-024-01992-0
28Y. Cui, W. Wang, H. Wang, B. Li, P. Zhao, F. Xuan, Cyclic behavior and damage mechanism of 304 austenitic stainless steel under different control modes, J Mater Res Technol, 30 (2024), 854-865, https://doi.org/10.1016/j.jmrt.2024.03.114
29N.-K. Wei, J. Shi, R.-D. Yang, J.-T. Xi, X.-M. Luo, X.-Y. Yin, R.-X. Zhang, Numerical Simulation and Experimental Analysis on Seam Feature Size and Deformation for T-Joint Laser–GMAW Hybrid Welding, Mater, 17 (2024), https://doi.org/10.3390/ma17010228
30A. K. Unni,M. Vasudevan, Determination of heat source model for simulating full penetration laser welding of 316 LN stainless steel by computational fluid dynamics, Mater Today: Proc, 45 (2021), 4465-4471, https://doi.org/10.1016/j.matpr.2020.12.842
31T. Kik, Heat Source Models in Numerical Simulations of Laser Welding, Mater, 13 (2020), https://doi.org/10.3390/ma13112653
32S. X. Hu, F. Li, P. Zuo, Numerical Simulation of Laser Transmission Welding-A Review on Temperature Field, Stress Field, Melt Flow Field, and Thermal Degradation, Polym, 15 (2023), https://doi.org/10.3390/polym15092125
33J. Liu, T. Jiang, Y. Shi, H. Zhu, Y. Dai, Numerical Simulation and Experimental Verification of Laser Multi-Section Welding, Chin J Mech Eng, 35 (2022), 125, https://doi.org/10.1186/s10033-022-00797-y
34N. Siva Shanmugam, G. Buvanashekaran, K. Sankaranarayanasamy, Some studies on weld bead geometries for laser spot welding process using finite element analysis, Mater Des, 34 (2012), 412-426, https://doi.org/10.1016/j.matdes.2011.08.005
35A. Shah, A. Kumar, J. Ramkumar, Analysis of transient thermo-fluidic behavior of melt pool during spot laser welding of 304 stainless-steel, J Mater Process Technol, 256 (2018), 109-120, https://doi.org/10.1016/j.jmatprotec.2018.02.005
36W. Zhu, F. Tang, Y. Ren, X. Yang, Y. Xu, Y. Xu, Influence of the residual welding stress on the corrosion propagation of the steel cages of the CRTS slabs in the high-speed railway, Constr Build Mater, 458 (2025), 139336, https://doi.org/10.1016/j.conbuildmat.2024.139336
37Y. Guo, Y. Teng, G. Liu, T. Jiao, Numerical study on creep-fatigue damage of titanium alloy pressure shell considering the effect of welding residual stresses, Thin-Walled Struct, 209 (2025), 112953, https://doi.org/10.1016/j.tws.2025.112953
38W. Sun, Y. Xia, M. Chen, G. Fan, A study on the role of local residual stress on the local strength and defect growth in laser-welded Ti-6Al-4V, J Alloys Compd, 1018 (2025), 179174, https://doi.org/10.1016/j.jallcom.2025.179174
39A. Kumar, S. M. Pandey, S. Sirohi, D. Fydrych, C. Pandey, P92 steel and inconel 617 alloy welds joint produced using ERNiCr-3 filler with GTAW process: Solidification mechanism, microstructure, mechanical properties and residual stresses, Heliyon, 9 (2023), e18959, https://doi.org/10.1016/j.heliyon.2023.e18959
40D. Guo, K. Yan, M. D. Callaghan, D. Daisenberger, M. Chatterton, J. Chen, A. Wisbey, W. Mirihanage, Solidification microstructure and residual stress correlations in direct energy deposited type 316L stainless steel, Mater Des, 207 (2021), 109782, https://doi.org/10.1016/j.matdes.2021.109782
Published
2026-04-02
How to Cite
1.
Peng J, Xia J, Xie S, Chen J, Zhang L, Jiu Y, Li Y, Yu X, Zhang X, Chen N. OPTIMIZATION OF LASER SPOT WELDING PARAMETERS FOR 304 STAINLESS STEEL THIN SHEETS USING NUMERICAL SIMULATION. MatTech [Internet]. 2026Apr.2 [cited 2026Jul.16];60(2):137–147. Available from: https://mater-tehnol.si/index.php/MatTech/article/view/1475
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