Optimization of weld bead geometry in laser welding with filler wire process using Taguchi’s approach

In the present work, laser welding with filler wire was successfully applied to joining a new-type Al–Mg alloy. Welding parameters of laser power, welding speed and wire feed rate were carefully selected with the objective of producing a weld joint with the minimum weld bead width and the fusion zone area. Taguchi approach was used as a statistical design of experimental technique for optimizing the selected welding parameters. From the experimental results, it is found that the effect of welding parameters on the welding quality decreased in the order of welding speed, wire feed rate, and laser power. The optimal combination of welding parameters is the laser power of 2.4 kW, welding speed of 3 m/min and the wire feed rate of 2 m/min. Verification experiments have also been conducted to validate the optimized parameters.

► Weld bead geometry is optimized in laser welding with filler wire using Taguchi’s approach.
► For upper width and fusion zone area, welding speed and wire feed speed are more significant.
► For lower width, only welding speed is significant on average S/N ratio.
► The optimum parameters were laser power 2.4 kW, welding speed 3 m/min and wire feed rate 2 m/min.
► Results of verification experiments are lying within the 95% confidence interval of the optimal range.