Infrared Physics & Technology 116 (2021) 103774

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Infrared Physics and Technology

journal homepage: www.elsevier.com/locate/infrared

Experimental investigation of the effect of laser parameters on the weld

bead shape and temperature distribution during dissimilar laser welding of
stainless steel 308 and carbon steel St 37
Xinmin Dong a, Guofang Wang b, *, Mohammad Ghaderi c
a
School of Mechanical and Power Engineering, Zhengzhou University, Henan 450001, China
b
Special Equipment Safety Inspection and Research Institute of Henan Province, Zhengzhou, Henan 450008, China
c
Independent Researcher, Rostock, Germany

A R T I C L E I N F O A B S T R A C T

Keywords: Fiber laser fusion welding of two applicable alloys including 308 stainless steel and low carbon steel (St 37) was
Fiber laser performed to assess the formation mechanism of the weld bead and temperature field near the fusion zone. In this
Molten pool research, some parameters including welding speed, laser power, nozzle distance, and beam deviation of the
Fusion zone
laser beam were determined as the main parameters. The results showed that the effect of the nozzle distance on
Temperature field
Weld bead
the temperature field was higher than that of the welding speed and laser power. It was also observed that
increasing the nozzle distance caused more absorption of the beam in the parts and there was an almost two-fold
increase in the dimensions and volume of the weld bead. The measured temperature near melt pool was
decreased about 120 ◦ C for st37 while a reduction about 30 ◦ C for stainless steel according to increasing nozzle
distance from 3 to 7 mm. Unlike carbon steel, the temperature of the stainless steel was clearly decreased at the
nozzle distance to the highest point. By increasing the welding speed, the temperature around the molten area
was decreased. The beam deflection parameter showed the effect of the temperature gradient index on changes
and a temperature decrease was observed by creating a distance from the location of thermocouples. Increasing
laser power from 300 to 400 W created wider weld bead about 40% and higher temperature about 40 ◦ C for
stainless steel in comparison to st37.

1. Introduction coefficient reduced the percentage of intermetallic components and the

In the recent decades, due to the advancement of technology, the use
of applicable techniques in joining different materials has received much
attention. Today’s methods for welding various joints are very complex
and diverse. For instance, laser welding, along with methods such as
friction welding and electron beam welding, is used to connect materials
to each other due to its unique properties [1–6]. This technology has
received attention in connecting similar and dissimilar materials. In this
regard, Benyounis et al. [7] investigated the effect of Co2 gas laser
welding parameters on the input heat and welding profile characteris­
tics. They welded medium carbon steel, showing that the welding speed
in welding conditions had the least effect, while the laser power had the
most effect on the weld profile. Torkamany et al. [8] also welded low-
carbon steel and aluminum 5754 using Nd: Yag laser. Their results
showed that by increasing the peak power, pulse duration and overlap
decrease of the mentioned parameters caused some destructive cracks.
Moradi et al. [9] also investigated the effect of pulsed laser welding
parameters on the weld quality, weld profile, weld penetration, weld
width and molten pool during welding of stainless steel and low carbon
steel sheets. Their results showed that the nozzle distance between the
laser and workpiece had a significant effect on the good penetration and
the molten pool. Further, using nitrogen gas and argon, Keskitalo et al.
[10] studied the laser welding operation on duplex stainless steel,
showing that higher welding speeds would reduce austenite levels and
brittleness. Chen et al. [11] also investigated the effects of pulse
numbers in the laser welding of titanium and stainless steel (CPTI)
sheets. Their results showed that the quality of welding, welding profile,
formation of intermetallic phases, mechanical properties and failure
mechanism were highly dependent on the pulse and its number. In
addition, Fernandes et al. [12] conducted pulsed laser welding of steel

* Corresponding author.
E-mail address: hwszzu@126.com (G. Wang).

https://doi.org/10.1016/j.infrared.2021.103774
Received 21 March 2021; Received in revised form 1 May 2021; Accepted 4 May 2021
Available online 7 May 2021
1350-4495/© 2021 Published by Elsevier B.V.
X. Dong et al.
sheets using heat treatment and optimal parameters. Their results
showed that some optimal parameters such as the effect of shielding gas
could greatly affect the geometry of the molten area and the weld
appearance. Kumar and Sinha [13] also performed butt laser welding of
St 37 carbon steel at a specified speed. The welding results and the
selected parameters of the laser could create the maximum tensile
strength with the base metal. Yazdian et al. [14] welded stainless steel
304L using a combined welding operation (electric arc and disc laser).
The purpose of this study was to evaluate the effects of speed and power
of laser on the welding area and reduction of pores. Their results showed
that the welding speed in arc welding, as compared to the disk laser,
significantly reduced the pores caused by the gas, forming a smooth
weld with a good appearance. Further, Sinha and Kumar [15] investi­
gated the effect of pulse width on dissimilar laser welding of S.S 304 L
and St 37 carbon steel. Their results showed that with changing the pulse
width, the welding profile was changed; so, with increasing the pulse
width up to 5 ms, a good penetration and quality connection were ob­
tained. Moradi et al. [16] welded AISI 410 martensitic stainless steel to
achieve a corrosion resistant surface. Their results showed that by
increasing the focal position, penetration depth and hardness were
decreased and with the lowest pulse energy, the highest corrosion
resistance was obtained. Akhiri Ardakani and Naffakh-Moosavy [17]
investigated the effects of pulsed Nd:Yag laser welding on Kovar and
AISI 304L alloys. Their results showed that raising the inlet heat led to
an increase in thermal stress and cracking in the weld profile. Saravanan
et al. [18] also conducted pulsed laser welding of stainless steel and
investigated the effect of heat input on the microstructures and me­
chanical properties. Their results indicated that raising the inlet heat led
to the formation of full penetration and increased the width of the joint
area; meanwhile, with moderate inlet heat, the maximum hardness and
weld penetration were decreased significantly. Khorram et al. [19] also
investigated the effect of laser parameters on the geometric dimensions
of the AISI 431 stainless steel hardened layer. Their results showed that
the optimal parameters of laser welding were the frequency of 17 Hz, the
pulse width of 18 ms, the welding speed of 20 mm/min, the focal po­
sition of 7.5 mm and the calculated microhardness of 650 HV. Further,
Yang et al. [20] investigated the microstructures and mechanical
properties in the laser welding operation of SU 304 steel plates with a
thickness of 100 mm. They performed the welding operation success­
fully by changing the deflection angle of the laser beam to less than 1◦ .
Their results showed a suitable connection with the appearance of a
smooth surface without any pores and cracks. Using the Nd: Yag laser
welding operation, Li et al. [21] investigated the porosity and cracking
of the heat-affected zone (HAZ) in the joint welding between SUS 304
stainless steel and copper. Their results showed that the only factor in
the loss of polygonal porosity was the regulation of the laser deflection
angle; by controlling the inlet temperature, the sensitivity to the HAZ
cracking could be greatly reduced. Ramesh et al. [22] also investigated
the microstructural properties and tensile behavior of A 558 low
strength alloy steel sheets under Nd: Yag laser welding. They increased
the welding speed from 70 mm/s to 120 mm/s and kept the other
welding parameters constant. Their results also showed that increasing
the welding speed led to the formation of ferrite in the fusion zone and
reduced the austenite size and dimensions of the molten zone.
In this study, dissimilar laser welding of stainless steel 308 and St 37
was performed. Joining dissimilar materials has been remarkably
growing in different industries. Hence, this experimental study was
carried out to investigate the effects of different process parameters on
the weld bead shape and temperature field. Analyzing the temperature
variation during the laser welding process could adequately control the
effects of the process parameters on the quality of the joint; this included
mechanical properties or surface appearance of the joint for industrial
applications.
2
Infrared Physics and Technology 116 (2021) 103774
2. Experimental procedure
In this experiment, a fiber laser with a maximum power equal to 500
W was used to join two dissimilar metals. The dimensions of the work­
pieces used were 50 × 20 × 1.5 mm. As shown in Fig. 1, to achieve the
temperature gradient during the welding process, all thermocouples (K
type) whose measurement accuracy was ± 1 were placed at a distance of
2 mm from the center of the melt pool. An Advantech USB 4780 module
card was then utilized to save and process the temperature data. The
chemical composition of the materials in weight percentages can be seen
in Table 1.
The laser welding process was performed by placing the parts on a
fixture. During welding, the effects of changing the parameters affecting
the quality of welding were investigated. These parameters were weld­
ing speed, nozzle distance and beam deviation.
3. Experimental design
The trend of changes in laser welding parameters is illustrated in
Table 2. Investigation and optimization of these parameters during
welding were done based on the appearance of the welding bead, and
thermophysical and metallurgical properties. The main objective of the
designed experiment was to analyze the effect of process parametes on
the temperature field and weld bead dimension simultaneously at low
cost and time. The most effective parameters can be distinguished as
well.
An experimental design for this process was considered to investigate
the trend of changes in the weld bead dimentions and appearance. The
most important factor affecting the changes in weld bead dimentions
and mechanical properties consisted of temperature variations. The
variation of the working parameters during experiments is illustrated in
Table 3.
4. Results and discussion
Due to the unique physical and chemical properties of the materials
during welding, good progress could be achieved in this field. By
creating a proper weld between two metals, the challenges involved in
using these metals in different industries could be addressed. Also, by
examining the appearance of the weld bead, the quality of the connec­
tion between the two metals could be partly analyzed. Also, by exam­
ining the appearance of the welding bead, an optimal speed for welding
could be achieved. In the following, the parameters and their effects on
the weld bead appearance were investigated.
4.1. Effects of laser parameters on the weld bead shape
Changes in process parameters during laser welding could greatly
affect the appearance of the weld bead. It is also very important to note
the laser beam interaction during laser welding. As mentioned, the
thermophysical properties of the two metals were different.
4.1.1. Welding speed effect
Fig. 2 shows the effect of the laser welding speed on the appearance
of a dissimilar weld bead composed of two metals. As could be observed
in Fig. 2b, as the laser welding speed was decreased from 500 to 300
mm/min, the width of the weld was increased and the overlap on the
surface of the weld bead was clearly increased as well. Also, the shape of
the weld bead was regular and convex, thus indicating the stable melting
condition of the two materials in acceptable conditions. No spattering or
defects, such as exccesive undercut or porosities, could be seen, ac­
cording to the combination of different alloys elements such as carbon
and chorome.
4.1.2. Laser power effect
Fig. 3 shows the effects of power on the appearance of the weld bead.
X. Dong et al. Infrared Physics and Technology 116 (2021) 103774

Fig. 1. Schematic of the experimental setup.

Table 1
Materials chemical composition used for experiments.
C Cr S Ni Mo Mn Si P Fe

S.S 308 0.03 19.5 9 2 0.6 0.03 Balance

St 37 0.102 0.005 0.49 0.15 0.019 Balance

and the process of evaporation, spraying and cavitation in the molten

Table 2
pool due to the formation of plasma during laser welding. Also, the
The selected parameters level used in experiments.
appearance of the welding bead was concave; this was due to the high
Parameter Welding Speed (mm/ Nozzle Distance Beam Deviation absorption of radiation on the surface of the molten pool, metal evap­
min) (mm) (mm)
oration and unstable welding conditions due to tension and plasma
Level 200–500 (+3)–(+7) (− 0.3)–(+0.3) formation. At the nozzle distance of +7 mm, a more stable and wider
variation
weld bead was formed at lower laser beam energy density; the bigger
laser beam diameter had a wider weld bead, which was about two folds
(2 mm), in comparison to the 1 mm weld bead at +5 mm nozzle
Table 3 distance.
The parameters used in the laser welding experiments.
Exp Welding Speed Peak Power Nozzle Distance Beam Deviation
(No) (mm/min) (W) (mm) (mm) 4.2. Effects of laser parameters on the temperature distribution
1 200 300 +7 0
2 300 300 +7 0 In this section, the effects of parameters variations, such as welding
3 300 300 +5 0 speed, laser power and nozzle distance, on the temperature distribution
4 300 400 +5 0 near the molten pool were investigated. Different thermal conductivities
5 300 400 0
of materials could essentially induce particular effects, leading to the
+7
6 300 400 +3 0
7 500 300 +7 0 formation of a bimetallic fusion zone. Therefore, by measuring the
8 500 400 +7 0 temperature distribution, the effect of laser parameters on the welding
9 500 400 +7 +0.3 condition and quality could be investigated.
10 500 400 +7 − 0.3

4.2.1. Effect of welding speed on the temperature distribution

According to Fig. 3b, with raising the laser power by 100 W, the width of
the weld bead and the volume of the melt in both metals sides were
evidently increased. As the laser power was enhanced, the density of
energy produced per unit time was increased, causing more melt volume
to form the weld joint. The width of the weld bead was increased from
1.3 mm to 2.2 mm, showing the augmentation of about 40%.
4.1.3. Nozzle distance effect
As shown in Fig. 4a, when welding at the nozzle distance of +5 mm
was performed, the shape of the weld bead was seen with a smaller
width than the nozzle distance of +7. Also, due to the high energy
density, a series of holes could be seen on the surface of the welding
bead, as can be seen in Fig. 4a, thus indicating the high energy density
Variation of the welding speed can create different temperature
gradients in the two sides of the workpiece, proportional to the thermal
conductivity coefficients of the workpieces. Due to the heterogeneity of
the ordinary carbon steel and stainless steel 308 and different thermal
conductivity coefficients, welding speed could have a direct impact on
the created temperature field. Therefore, in order to achieve a propor­
tional melt pool in terms of dimensions, selecting the optimal welding
speed is of particular importance. As can be seen in Fig. 5a, the increase
in workpiece temperature and cooling rate in carbon steel was associ­
ated with the higher thermal conductivity coefficient of this alloy. Due
to the same condition of both parts in receiving the laser beam energy,
the created temperature and cooling rate for stainless steel 308, ac­
cording to Fig. 5b, were less than those for carbon steel. The maximum
temperature created for stainless steel was about 160 ◦ C at the welding

3
X. Dong et al.
Fig. 2. Effect of welding speed on weld bead formation and shape at laser power of 400 W, nozzle distance of 2 mm, and welding speed of (a) 500 mm/s, (b) 300
mm/s.
Fig. 3. Effect of laser power on weld bead formation and shape at welding speed of 500 mm/s, nozzle distance of 2 mm, and laser power of (a) 300 W, (b) 400 W.
speed of 200 mm/min; for carbon steel, it was about 190 ◦ C.
It could also be seen that with increasing the welding speed to 300
mm/min, the temperature decrease rate was about 10 ◦ C due to the
higher thermal conductivity coefficient for carbon steel; this was about
40 ◦ C for stainless steel owing to the lower thermal conductivity coef­
ficient. On the other hand, by increasing the welding speed to 500 mm/
min, the temperature of both metals was almost the same, thus indi­
cating the low rate of input energy given to the workpiece and different
thermal conductivity coefficients. Due to the lower thermal conductivity
coefficient, stainless steel was more sensitive to the changes in the
welding speed, as compared to carbon steel, in terms of the temperature
gradient.
4.2.2. Effect of laser power on the temperature distribution
Fig. 6a shows that the temperature changes in low carbon steel were
20 ◦ C higher than those in stainless steel at 400 W due to the higher
thermal conductivity coefficient and the greater absorption of the laser
beam by carbon steel. On the other hand, Fig. 6b shows that the
reduction of the laser power significantly reduced the temperature
generated in stainless steel, which could be due to the significant
4
Infrared Physics and Technology 116 (2021) 103774
changes in the absorption coefficient of the laser beam at the lower
power and its lower absorption at a power lower than that of carbon
steel. The temperature changes for stainless steel at 300 W, as compared
to 400, was about 60 ◦ C; meanwhile, temperature changes for carbon
steel were about 20 ◦ C. On the other hand, it could be said that with
increasing the temperature, high thermal accumulation occurred in
stainless steel, as compared to carbon steel.
4.2.3. Effect of nozzle distance on the temperature distribution
Fig. 7a shows that by reducing the nozzle distance, the temperature
for carbon steel was increased significantly. As a result, the temperature
around the molten pool reached its highest value (approx. 300 ◦ C); also,
with incrasing the nozzle distance from the surface of the workpiece, the
temperature was decreased, approaching 200 ◦ C. By moving the nozzle
distance to the higher distance from the workpiece surface, the tem­
perature was raised again, by about 30 ◦ C, which could be due to the
changes occurring in the size of the laser beam diameter and its prox­
imity to the thermocouple; the laser beam did not enter the molten pool.
In this case, the energy density in the center of the pool was lower and
the amount of the melt was less and more energy was spent on heating
X. Dong et al. Infrared Physics and Technology 116 (2021) 103774

Fig. 4. Effect of nozzle distance on the weld bead shape at laser welding speed 300 mm/min, laser power of 300 W, and nozzle distance of (a) +5 mm, (b) +7 mm.

Fig. 5. Effect of welding speed on the temperature near the melt pool at laser power of 300 W, nozzle distance of 2 mm and beam deviation of 0 mm for (a) St 37, (b)
stainless steel 308.

Fig. 6. Effect of laser power on the temperature near the melt pool at welding speed of 300 mm/min, nozzle distance of 2 mm and beam deviation of 0 mm for (a) St
37, (b) stainless steel 308.

5
X. Dong et al.
Fig. 7. Effect of nozzle distance on the temperature near the melt pool at laser power of 400 W, welding speed of 300 mm/min and beam deviation of 0 mm for (a) St
37, (b) stainless steel 308.
the areas around the melt pool.
Fig. 7b shows the temperature graph for stainless steel with respect
to nozzle distance changes. The highest temperature was seen in the area
around the molten pool, which was about 230 ◦ C. By further decreasing
the distance of the nozzle from the surface, the workpiece temperature
was dropped about 20 ◦ C, which was due to the relative evaporation and
absorption of more laser beam in the molten material. Unlike carbon
steel, the temperature was clearly decreased at the nozzle distance to the
highest point.
4.2.4. Effect of beam deviation on the temperature distribution
In general, in order to investigate the effect of beam deviation on the
thermal gradient created around the molten pool, the laser beam was
diverted to stainless steel or carbon steel by 0.3 mm, respectively. The
temperature obtained by the thermocouples in both metals was
measured at the previously specified position. As can be seen in Fig. 8,
the deviation of the laser beam towards the low carbon steel indicated
that the temperature around the molten pool had been increased to
about 210 ◦ C for the low carbon steel. This was as if the temperature had
risen only to 100 ◦ C for stainless steel. Therefore, displacement of laser
beam radiation could have a significant effect on the temperature
gradient. On the other hand, as shown in Fig. 8b, the deviation of the
laser beam towards stainless steel increased the temperature to about
170 ◦ C, which was decreased by 40 ◦ C, as compared to the low carbon
steel. The temperature of carbon steel in this experiment was about
Fig. 8. Effect of beam deviation on the temperature near the melt pool at laser power of 400 W, welding speed of 500 mm/min and nozzle distance of 2 mm for (a) St
37, (b) stainless steel 308.
6
Infrared Physics and Technology 116 (2021) 103774
100 ◦ C, which was almost the same as that of stainless steel in the pre­
vious experiment (deviation towards carbon steel).
Since different thermal conductivity coefficients of about 16 W/m.K
for stainless steel and 48 W/m.K were obtained for carbon steel, the
temperature created by the deflection of the beam towards carbon steel
was higher. On the other hand, increasing the distance from the contact
point of the two metals caused the measurement of temperature to be
almost similar for the other metal. Therefore, it could be said that
changing the location of the laser beam caused a sharp decrease in the
thermal gradient at the temperature measuring point in the metal, which
was farther away from the laser beam. In addition, due to the difference
in thermal conductivity coefficients between carbon steel and stainless,
steel and the same distance of about 2.3 mm from the laser beam, the
temperature measured at this point on carbon steel and stainless steel
was almost the same, mostly due to thermal conductivity.
4.3. Melt pool dimensions and microstructure
The microstructure of two dissimilar metals and their molten pool is
of particular importance. To perform this process, it is first necessary to
accurately determine the microstructure of each material and then using
metallographic methods, especially the general and partial microstruc­
ture of the molten pool in different areas, investigate the participation of
each of the specified metals in the molten pool. The microstructure of
the base metal of St 37, as shown in Fig. 9a, included the ferrite structure
X. Dong et al.
Fig. 9. Microstructure of base metal (a) St 37, (b) S.S 308.
with the distribution of semantite particles. The microstructure of
stainless steel as a second base metal is ALSO shown in Fig. 9b. As
shown, the stainless steel 308 consisted of austenitic microstructure with
twin zones and ferrite filaments.
The microstructure was obtained by the laser welding process on
carbon steel and stainless steel included different areas. In the molten
pool area, the dominant structure consisted of tempered martensite. In
Fig. 10, due to the high thermal gradient in the molten pool and
receiving the highest energy density in this area, the workpiece received
the highest heating and cooling rates, which leads to the formation of
tempered martensite microstructure in this area. In the area of contact of
the molten pool with the stainless steel region, the dominant micro­
structure included the austenitic structure, along with the twin regions
and delta ferrite filaments. Therefore, it can be said that there are no
significant microstructural changes in stainless steel during the laser
welding process. It can also be concluded that in the welding process of
these two metals, the microstructural changes in carbon steel are much
greater than in stainless steel and therefore the rate of temperature
changes can be higher.
5. Conclusion
In this paper, the effects of laser parameters determined for welding
operations were investigated. Welding speed, laser power, nozzle
Fig. 10. The microstructure of the molten pool in two magnifications: (a) 100× magnification, (b) 500× magnification.
7
Infrared Physics and Technology 116 (2021) 103774
distance and beam deviation were each examined separately in several
different amplitudes:
The results of the experiment showed that the thermal conductivity
of the applied alloys played an effective role among all determined pa­
rameters, causing the absorption of laser energy and heat retention in
the parts.
welding speed which controls the heat input rate per unit time had a
crucial role on the temperature field.
The laser power had a significant effect on both the temperature
field, and dimensions and volume of the melt area. By changing the
input power density, the amount of the heat applied to the alloys used
was different, which could be attributed to the heat received by each of
the alloys.
Nozzle distance was another parameter thus decreasing the distance
and increasing the temperature around the molten area; so, nozzle dis­
tance caused more absorption of the beam in the parts. For this study
experiments, there was an almost two-fold increase in the dimensions
and volume of the weld bead. The temperature near melt pool was
decreased about 120 ◦ C for st37 while a reduction about 30 ◦ C for
stainless steel.
Furthermore, there was no significant microstructural changes in
stainless steel during the laser welding process and in the welding pro­
cess of these two metals, the microstructural changes in carbon steel
were much greater than in stainless steel and therefore the rate of
X. Dong et al.
temperature changes can be higher.
Declaration of Competing Interest
The authors declare that they have no known competing financial
interests or personal relationships that could have appeared to influence
the work reported in this paper.
Acknowledgement
This work was sponsored in part by Key Research and Development
and Promotion Special Project of Henan Province (212102210351).
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