Optimization of Laser Butt Welding Parameters for Al-3Mg-Si Aluminium Alloy Sheet Using Response Surface Methodology

R Kumar; V Gautam

doi:10.5750/ijme.v168iA4(S).1912

Published: Oct 10, 2026

DOI: https://doi.org/10.5750/ijme.v168iA4(S).1912

Keywords:

Laser welding Al-3.15Mg-Si aluminum alloy Response surface methodology (RSM) Mechanical properties Microstructural characterization

R Kumar

Delhi Technological University, New Delhi, India

V Gautam

Delhi Technological University, New Delhi, India

Abstract

Laser welding joins thin aluminum alloy sheets in lightweight structural applications, yet strong, ductile joints require precise welding settings. Laser-welded 1.5 mm Al-3.15Mg-Si aluminum alloy sheet with RSM optimization. We tested industrial robotic fiber laser welding. A 20-run face-centered central composite design (FCCCD) examined how laser power (2200–3000 W), welding speed (50–80 m/min), and pulse length (2–10 ms) effect welded joint. Response variables were UTS and elongation. Experimental results demonstrated that welding parameters significantly affect joint performance. The lowest joint performance was 2200 W laser power, 50 m/min welding speed, 10 ms pulse length, 36.2 MPa UTS, and 0.31% elongation. The best UTS was 133 MPa with 1.6% elongation at 3000 W laser power, 65 m/min welding speed, and 6 ms pulse length. RSM statistics matched experiments. EBSD-analyzed weld bead microstructure of lowest and best RSM and base metal samples.

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Vol. 168 No. A4(S) (2026): Special Issue: International Conference of Advance Research and Innovation

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