This paper investigates the application of dynamic beam shape sequencing to improve process control, stability, and quality in thick-section laser welding and metal additive manufacturing. Traditional welding and additive processes typically rely on a static beam profile, which limits flexibility in controlling melt pool dynamics, penetration behavior, and thermal distribution, particularly in high-power and thick-material applications.

The study demonstrates how real-time sequencing of multiple beam shapes within a single process cycle enables independent optimization of critical process stages. By dynamically modifying the beam geometry, it becomes possible to tailor energy deposition for keyhole initiation, deep penetration, sidewall fusion, and controlled solidification. This approach allows improved weld integrity in thick sections, including better root fusion and reduced defect formation.

In metal additive manufacturing, particularly directed energy deposition, beam shape sequencing enables control over bead geometry, layer bonding, and dilution. Experimental and production-scale trials show improved track uniformity, enhanced layer adhesion, and reduced porosity compared to fixed beam configurations. The dynamic control of heat input also minimizes residual stress and distortion.

The paper presents quantitative results comparing static and dynamic beam strategies, including penetration depth, melt pool stability, and defect rates. Integration into automated manufacturing systems and process parameter optimization are discussed. The findings demonstrate that beam shape sequencing significantly expands the processing window, improves repeatability, and enhances overall part quality. This technology provides a versatile tool for advancing both thick-section welding and metal additive manufacturing applications.