Modeling and Optimization of Dissimilar Laser Welding

The aim of this research is to predict and optimize laser welding of some ‎economically important dissimilar materials in industry through applying a Taguchi ‎orthogonal array design as a DOE approach to design the experiments, develop ‎mathematical models and optimize the welding operation. This was achieved by ‎controlling selected welding parameters; laser power, welding speed and focus ‎position, to relate the mechanical properties, weld bead geometry, principal residual ‎stress and unit operating cost to the selected input welding parameters. The dissimilar ‎materials studied in this work are low carbon steel, 316 stainless steel, titanium G2, ‎different types of aluminium alloys such as (6082, 5251H22 and 1050H24) with ‎different thicknesses and different joint designs. ‎ For each dissimilar welded material, mathematical models were developed to ‎predict the required responses. Moreover, the main effects and the interactions ‎effects of the process parameters on the responses were discussed and presented ‎graphically for all dissimilar materials and joint designs. Furthermore, the developed ‎models were optimized by determining the best combinations of input process ‎paramete