Ferroelectrics

ISSN: 0015-0193 (Print) 1563-5112 (Online) Journal homepage: http://www.tandfonline.com/loi/gfer20

Optimization and metallurgical studies of CO2

laser welding on austenitic stainless steel to
carbon steel joint

M. P. Prabakaran & G. R. Kannan

To cite this article: M. P. Prabakaran & G. R. Kannan (2017) Optimization and metallurgical
studies of CO2 laser welding on austenitic stainless steel to carbon steel joint, Ferroelectrics, 519:1,
223-235, DOI: 10.1080/00150193.2017.1362270

To link to this article: https://doi.org/10.1080/00150193.2017.1362270

Published online: 05 Dec 2017.

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 FERROELECTRICS
2017, VOL. 519, 223–235
https://doi.org/10.1080/00150193.2017.1362270

Optimization and metallurgical studies of CO2 laser welding

on austenitic stainless steel to carbon steel joint
M. P. Prabakarana,b and G. R. Kannana,b
a
Department of Mechanical Engineering, NPR College of Engineering and Technology, Dindigul, Tamilnadu,
India; bDepartment of Mechanical Engineering, PSNA College of Engineering and Technology, Dindigul,
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Tamilnadu, India

ABSTRACT ARTICLE HISTORY

In the present work, the 4 kW CO2 laser welding process has been Received 7 November 2016
optimized for austenitic stainless steel (AISI 316)/ low carbon steel (AISI Accepted 6 June 2017
1018) joint by using Taguchi based grey relational analysis. The KEYWORDS
experimental results make clear that the AISI 316/AISI 1018 laser CO2 laser welding; dissimilar
welded joints are effectively enhanced by optimizing the input metals; optimization;
parameters. The metallurgical studies have been carried out for the mechanical properties;
optimum welded samples using an optical microscope to observe metallurgical properties
weld appearance and energy dispersive X-Ray analysis carried out to
measure the nature of the matrix and chemical element distribution in
the weld interface.

1. Introduction
The laser beam welding offers many advantages like low and precise heat input with
narrow heat affected zone and low distortion. Laser welding has many potential
benefits compared to other welding process like the unique combination of deeper
penetration, high welding speed, high precision, reliability, high efficiency and high
productivity. ASS and CS are widely used in the fabrication of structural components
in the fusion reactors due to their superior mechanical properties at elevated tempera-
tures, resistance against corrosion and better creep rupture properties. The laser beam
welding attracted nuclear sector applications like fission and fusion reactor compo-
nent fabrications [1]. ASS to CS can be joined by using CO2 laser machine without
using filler materials. The effect of the laser process parameters laser power, welding
speed and shielding gas flow rate on the weld joint tensile strength have been investi-
gated. Sun et al. [2] CO2 laser welding uses around 99% of all TWBs applications.
Laser welding is quick, precise, reliable and able to join a wide variety of materials
varying in thickness. Akbari Mousavi et al [3] discuss metallurgical study of pulsed
Nd: YAG laser welding of AISI 321 and AISI 630 stainless steels. They establish very
fine cellular and dendritic austenite structures achieved in the weld zone. Torkamany
et al. [4] reported the effect of dissimilar laser welding mode on microstructure and

CONTACT M. P. Prabakaran prabakaranmp89@gmail.com

Color versions of one or more of the figures in the article can be found online at www.tandfonline.com/gfer.
© 2017 Taylor & Francis Group, LLC
 [798]/224 M. P. PRABAKARAN AND G. R. KANNAN

mechanical performance of low carbon to austenitic stainless steel and revealed that
the size of fusion zone and the dilution percentage of low carbon steel is highly
dependent on the transition of laser welding mode from conduction to keyhole.
Anawa et al. [5] investigated the dissimilar LBW of stainless steel and low carbon
steel using statistical methods and reported that the welding speed and laser power
have a significant effect on weld bead characteristics. An orthogonal array (OA) pro-
vides a set of well balanced experiments and Taguchi’s signal-to-noise ratios (S/N),
which is the logarithmic functions of expected output serve as objective functions
for optimization. This assists in data analysis and the prediction of optimum results
[6, 7]. The Taguchi method combined with gray relation analysis solve the multi-
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criteria optimization problems in CO2 laser welding processes. In this technique, the
gray relational grade has been applied to convert multiple quality characteristics into
single performance characteristics [8]. Gray relation analysis combined with the Tagu-
chi method to find the optimum parameter setting for laser micro-drilling of alumina.
The results of the optimal setting revealed that there is remarkable development in
the laser micro-drilling process [9]. Taguchi is the developer of the Taguchi technique
[10]. In this work, the Taguchi method uses a design of L9 orthogonal arrays to
undergo the entire parameter space with only a meager sum of experiments. Taguchi
methods has been extensively utilized in engineering analysis and consists of a pro-
posal of experiments with an objective of acquiring information in a controlled way,
in order to incur data about the weld strength. The metallurgical studies have been
carried out for the optimum weld samples by using an optical microscope and EDX
carried out to measure the nature of the chemical element distribution in the weld
interface.

2. Experimental procedure
2.1. Materials
In this investigation, low carbon steel AISI 1018 to austenitic stainless steel AISI 316 with the
dimension of 100 £ 100 £ 6 mm was used to get square butt joint in single pass weld. The
base material plates are cut by wire cut electro discharge machining; the surface edges are
finely finished and cleaned with suitable chemicals before the welding process. The chemical
composition of these base metals is listed in Table 1 and 2 respectively.

2.2. CO2 laser welding machine

The experiments were performed with 4kW CO2 laser (TRUMPF TLC1005) with the spot
diameter of the laser beam was 0.15 mm, focused by a 20 mm focal length lens. The accuracy
of the machine smallest programmable increment 0.01 mm, Medium positioning accuracy

Table 1. Chemical composition of ASS AISI 316.

Elements C Si Mn P S Cr Mo Ni Fe

Wt% 0.024 0.28 1.44 0.041 0.017 16.95 2.06 10.09 Balance
 FERROELECTRICS [799]/225

Table 2. Chemical composition of LCS AISI 1018.

Elements C Si Mn P S Ni Fe

Wt% 0.12 0.105 0.60 0.015 0.012 0.023 Balance

§ 0.1 mm and Repeatability § 0.03 mm. Working range X-Axis 4000 mm, Y-Axis 1500 mm,
Z-Axis 500 mm, C- Axis n £ 3600, B-Axis § 1200 and A-Axis n £ 3600. The plates were
properly positioned and clamped using the special fixture.

2.3. Experimental design

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Laser welding process parameters such as laser power, welding speed, gas flow rate and focal
distance are affecting the quality of weld samples. In this study, three process parameters,
namely laser power (P), welding speed (S) and gas flow rate (G) were considered for the pur-
pose of analysis [11]. Experiments were designed by the Taguchi L9 OA was composed of
three columns and 9 rows. This design was selected based on three LBW welding process
parameters with three levels each. Before the experiment, preliminary trials were made to
achieve visually acceptable joints. The process parameters employed in the experiment are
listed in Table 3.

2.4. Mechanical properties

The tensile test was carried out in 100kN, computer controlled universal testing machine
(UTM). Welded joints were sliced by using wire cut Electro Discharge Machining (EDM)
and nine transverse tensile specimens were prepared to required dimensions as per AST-
ME8M-04. The specimen is loaded as per ASTM specifications so that the tensile specimens
undergo deformation. The identification of the hardness of metallic materials is measured
by pressing a small rounded indenter against a clean surface with a specific force. The
machine producing the indention also measures its depth and renders a numerical value for
that depth. The Rockwell B scale evinces more accuracy in the hardness measurement of
metallic materials. The experimental value of tensile strength and average hardness is given
below Table 4.

3. Result and discussion

3.1. Orthogonal array experiment and the S/N ratio
In this study, nine experiments were needed to analyze the welding parameters using the L9
orthogonal array. In order to evaluate the influence of each selected factor on the responses,
Table 3. LBW process parameters and their levels.
Levels

S. no. Process parameters Units Notation ¡1 0 C1

1 Laser power W P 3000 3150 3300

2 Welding speed m/min S 0.5 0.7 1.0
3 Gas flow rate (lit/min) G 18 20 22
 [800]/226 M. P. PRABAKARAN AND G. R. KANNAN

Table 4. Combination of laser parameters in L9 orthogonal array.

Experiment Laser power W Welding speed m/min Gas flow rate, lit/min Weld strength N/mm2 Average
no. (P) (S) (G) (WS) hardness

1 3000 0.50 18 481.349 36

2 3000 0.75 20 473.924 19
3 3000 1.00 22 453.927 25
4 3150 0.50 20 527.027 41
5 3150 0.75 22 501.682 19
6 3150 1.00 18 467.632 26
7 3300 0.50 22 535.443 44
8 3300 0.75 18 497.765 16
9 3300 1.00 20 485.787 21
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the S/N ratios for each control factor had to be calculated. The signals indicated that the
effect on the average responses and the noises were measured by the effect of the deviations
from the average responses, which would designate the sensitiveness of the experimental
output to the noise factors. The suitable S/N ratio must be chosen by using previous knowl-
edge, expertise and understanding of the process. When the target is fixed and there is a triv-
ial or absent signal factor (static design), it is feasible to select the S/N ratio depending on the
goal of the design. In this study, the S/N ratio was chosen according to the criterion the-big-
ger-the-better so as to maximize the responses [12, 13]. The S/N ratio for “bigger is better”
target for all the responses was calculated as following equation (1).

X 
1 6 y2
S 6 N D ¡ 10 log10 (1)
n

where y is the average measured tensile strength and n the number of experimental runs, in
this study n D 9. The experimental lay-out for the welding process parameters using the L9
orthogonal array is shown in Table 5 and the responses for S/N ratio are presented in Table 6.
The main effect plots exhibited in Fig. 2 and 3 shows how each factor affects the response
characteristic. This can present the different levels of a factor that affects the characteristic
differently. The main effect plot created by MINITAB plots the characteristic average for
each factor level. The rank 1 in Table 6 indicates that laser power parameter (1) has a stron-
ger effect on the process followed by rank (2) welding speed, which has medium effect, while
rank (3) has minimum effect on the process.

Table 5. Experimental assignments S/N ratio.

Experiment Laser power Welding speed m/ Gas Flow Rate, lit/ S/N Ratio weld S/N Ratio average
no. W (P) min (S) min (G) strength hardness

1 3000 0.50 18 53.6492 31.12

2 3000 0.75 20 53.5142 25.57
3 3000 1.00 22 53.1397 27.95
4 3150 0.50 20 54.4367 32.25
5 3150 0.75 22 54.0086 25.57
6 3150 1.00 18 53.3981 28.29
7 3300 0.50 22 54.5743 32.86
8 3300 0.75 18 53.9405 24.08
9 3300 1.00 20 53.7289 26.44
 FERROELECTRICS [801]/227

Table 6. Response for S/N ratio.

Level Laser power (W) Welding speed (m/min) Gas flow rate (lit/min)

1 53.43 54.22 53.66

2 53.95 53.82 53.89
3 54.08 53.42 53.91
Delta 0.65 0.80 0.24
Rank 2 1 3

3.2. ANOVA table

In the ANOVA table (Table 7), the F value is used to test the significance of a factor by com-
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paring model variance with residual variance, which is calculated by dividing the model
mean square by the residual mean square. If the variance values are near to each other, the
ratio will be close to one and it is less likely that any of the factors have a significant effect on
the response. A high F value for a parameter means that the effect of the parameter on the
characteristics is large. The result in Table 7 shows that the highest F value in the process
was obtained for laser power P equal to 2.46. The F value for the speed S was equal to 27.31,
which shows that the speed has a relatively higher effect on the process. Adequate precision
compares the range of the predicted values at the design points to the average prediction
error. The same table also explains the other adequacy measures R2 and adjusted R2. All the
adequacy measures notice that an adequate model has been obtained.

3.3. Gray relational analysis and discussion on experimental results

The gray relational analysis is a quantitative analysis on exploring the similarity and dissimi-
larity among factors. It uses the gray relational grade to find the correlation degree of factors.

Figure 1. Shows a graphic view of the experimental setup and the laser delivery system with workstation.
 [802]/228 M. P. PRABAKARAN AND G. R. KANNAN
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Figure 2. Tensile specimens after testing.

In the GRA, the first step is to perform the normalization of experimental data to make the
range within 0 to 1. This step is called gray relational generating (GRG). The GRG also
expresses the deviation between the experimental value and the ideal value. According to
importance of quality characteristics, there are three criteria for optimization in gray rela-
tional analysis, namely “larger-the better,” “smaller-the-better,” and “nominal-the-best”
[14]. Then overall Grey relational grade is determined by averaging the Grey relational coef-
ficient corresponding to selected responses. The overall performance characteristic of the
multiple response process depends on the calculated Grey relational grade. The optimal fac-
tor setting for maximizing overall Grey relational grade can be performed by Taguchi
method.

Figure 3. Effect of the laser welding parameters on the weld strength S/N ratio.
 FERROELECTRICS [803]/229

Table 7. ANOVA for weld strength.

Source DF Seq SS Adj SS Adj MS F P

Laser power 2 2240.19 2240.19 1120.09 120.07 0.008

Welding speed 2 3105.23 3105.23 1552.62 166.43 0.006
Gsa flow rate 2 397.89 397.89 198.94 21.33 0.045
Error 2 18.66 18.66 9.33
Total 8 5761.97
R-Sq D 99.68% R-Sq(adj) D 98.70%

In the present analysis, the higher value of weld strength indicates better strength perfor-
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mance, therefore the “higher-the-better” criterion is chosen for weld strength. On the other
hand, the lower value of hardness represents better hardness performance, therefore the
“lower-the-better” is chosen for them. In Grey relational generation, the normalized WS is
corresponding to the higher-the-better (HB) criterion which can be expressed as eq. (2).

yi ðkÞ ¡ min yi ðkÞ

xi ðkÞ D (2)
max yi ðkÞ ¡ min yi ðkÞ

where, xi (k) and yi (k) are the sequence after the data preprocessing and comparability
sequence respectively, k D 1 for WS; i D 1, 2, 3…, 9 for experiment numbers 1 to 9. In Grey
relational generation, the normalized WS is corresponding to the lower-the-better (LB) crite-
rion which can be expressed as eq. (3).

max yi ðkÞ ¡ yi ðkÞ

xi ðkÞ D (3)
max yi ðkÞ ¡ min yi ðkÞ

where, xi (k) and yi (k) are the sequence after the data preprocessing and comparability
sequence respectively, k D 2 for HD; i D 1, 2, 3…, 9 for experiment numbers 1 to 9. Similarly
the remaining calculations are also made and all the sequences after data preprocessing using
equations (2) and (3) are presented in Table 8.

Dmax D D07 ð1Þ D D08 ð2Þ D 1:000

Dmin D D03 ð1Þ D D07 ð2Þ D 0:000

Now D0i is the deviation sequence of the reference sequence x0 (k) and the comparability
sequence xi (k) the deviation sequence presented in Table 8.

D0i ðkÞ D j x0 ðkÞ ¡ xi ðkÞ j (4)

The definition of Grey relational grade in the course of Grey relational analysis is to reveal
the degree of relation between the 9 sequences [x0 (k) and xi (k), i D 1, 2, 3, …,9]. The Grey
 [804]/230 M. P. PRABAKARAN AND G. R. KANNAN

Table 8. The sequences of each performance characteristic after data processing and deviation sequences.
Sequences of performance Deviation sequences

Experiment no. WS H D0i (1) D0i (2)

Reference sequence 1.0000 1.0000 1.0000 1.0000

1 0.336 0.286 0.664 0.714
2 0.245 0.893 0.755 0.107
3 0.000 0.679 1.000 0.321
4 0.897 0.107 0.103 0.893
5 0.586 0.893 0.414 0.107
6 0.168 0.643 0.832 0.357
7 1.000 0.000 0.000 1.000
8 0.538 1.000 0.462 0.000
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9 0.391 0.821 0.609 0.179

relational coefficient ji (k) can be calculated by using equation (5) presented Table 9.

Dmin ¡ cDmax
ξ i ðkÞ D (5)
D0i ðkÞ ¡ cDmax

After averaging the Grey relational coefficients, the Grey relational grade g i can be com-
puted by using equation (6) presented Table 9.

1P
kD1
gi D ξ ðk Þ (6)
n n i

where n is the number of process responses. The higher value of the Grey relational grade
corresponds to an intense relational degree between the reference sequence x0 (k) and the
given sequence xi (k). The reference sequence x0 (k) represents the best process sequence;
therefore, higher Grey relational grade means that the corresponding parameter combina-
tion is closer to the optimum. Since the experimental design is orthogonal, it is then possible
to separate out the effect of each welding parameter on the grey relational grade at different
levels. The mean of the grey relational grade for each level of the welding parameters is sum-
marized and shown in Table 9.

Table 9. Grey relational coefficients.

Grey relational coefficient

Experiment no. WS ξ i (1) H ξ i (2) Grey relational analysis g i D 1/2 (ξ i (1) C ξ i (2)) Rank

1 0.430 0.412 0.421 9

2 0.399 0.824 0.611 4
3 0.333 0.609 0.471 8
4 0.829 0.359 0.594 5
5 0.547 0.824 0.685 2
6 0.375 0.583 0.479 7
7 1.000 0.333 0.667 3
8 0.520 1.000 0.760 1
9 0.451 0.737 0.594 6
 FERROELECTRICS [805]/231

Table 10. Response table for the grey relational grade.

Levels

S. no. Process parameters Level 1 Level 2 Level 3 Main effect (max-min) Rank

1 Laser Power 0.501 0.585 0.673 0.172 1

2 Welding Speed 0.560 0.685 0.514 0.171 2
3 Gas Flow Rate 0.566 0.584 0.608 0.042 3

3.5. Energy dispersive X-ray (EDX)

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The distribution of dissimilar elements across weld interface and element distribution in
diverse parts is measured by optimum parameters using Energy Dispersive X-ray (EDX).
This investigation is carried out for the dissimilar material LCS AISI1018 and ASS AISI 316.
The LBW is done for the two dissimilar materials and the EDAX analysis is done to examine
the distribution and effect of chemical composition between LCS/ASS at the weld interface.
The result shows weld zone with more amounts Fe with an intermediate level of Cr and Ni
in Fig. 5. It provides sufficient mechanical properties and high corrosion resistance of the
joint.

3.6. Microstructural analysis

In order to observe the microstructure under the optical microscope, specimens were
cut from the weld by wire cut EDM process and samples were prepared using con-
ventional metallographic methods. Transversely oriented weld sample was embedded
into a Bakelite mould in order to facilitate surface preparation of grinding and

Figure 4. Effect of the laser welding parameters on the hardness S/N ratio.
 [806]/232 M. P. PRABAKARAN AND G. R. KANNAN
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Figure 5. EDX Result for weld interface.

polishing in accordance with ASTM E3 standard and etched as per the ASTM E407
procedure. The microstructural examination has been carried out by optical micro-
scope for detailed observations. The macro weld section samples are finely polished
and etched with oxalic acid to examine the microstructure of heat affected zone
(HAZ) and weld zone (WZ). Fig. 6(b), in the base metal AISI316, it can be observed

Figure 6a. Microscopic structure of HAZ in LCS AISI 10158.

 FERROELECTRICS [807]/233
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Figure 6b. Microscopic structure of HAZ in ASS AISI316.

those ferrite fingers are dispersed in the austenitic matrix. Equiaxed dendrites are
formed due to rapid cooling during weld metal solidification. In the heat affected
zone of AISI316 more chromium carbide precipitation are present. This is due to the
migration of chromium from the parent metal to the HAZ and this happened because
of heat, generated during welding. In Fig. 6(c) at the weld interface the grain size is
coarse due to ferrite failure occurred during the weld. The weld zone is mostly occu-
pied by equiaxed dendrites, which has nucleated at the fusion boundary, and grown
towards the centre of the molten pool. The subsistence of dendritic structure is signif-
icant due to the high cooling rate observed in the laser welded melt pool.

Figure 6c. Weld zone.

 [808]/234 M. P. PRABAKARAN AND G. R. KANNAN

4. Conclusion
The GRA based on the Taguchi method’s response table has been proposed as a way of
studying the optimization of CO2 LBW process parameters for ASS AISI 316/LCS
AISI1018 joint. The optimal welding parameters have been determined by the grey rela-
tional grade for multi performance characteristics that is weld strength and average hard-
ness. The average grey relational grade, it is found that the largest value of the grey
relational grade for laser power, welding speed and gas flow rate are 3300 W, 0.75 m/min
and 22 lit/min respectively. Welding speed is the main factor affecting the response. The
laser power also has a strong effect on the response increasing welding speed leads to a
decrease in response. But the gas flow rate had a small effect on the tensile strength of the
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produced welded components. A confirmation experiment was also conducted in order to

validate the optimal process parameters values. The excellent to observe the weld appear-
ance and mechanical properties indicate that high power CO2 laser welding of AISI 316/
AISI1018 6 mm thick plates is realistic in industrialized applications. A primarily homoge-
nous microstructure and well mixed fusion zone was produced with a specific point energy
of dissimilar metal joint.

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