/ Program 45th Annual Icaleo Laser Materials Macroprocessing TBD Effect of Static and Dynamic Laser Beam Shaping On Fe-Al Intermetallic Formation In Al-Si Coated 22MnB5 Steel
Description

Laser beam welding of Al-Si coated 22MnB5 steel is challenging due to Al enrichment from the Al-Si coating, which promotes α-ferrite and Fe(Al,Si) intermetallic (IMC) formation, degrading joint performance. This study examines the effect of static-in-source fibre and dynamic beam shaping using a coherent beam combining (CBC) laser system during overlap welding, comparing core-only, static core/ring, and forward-triangle dynamic beam configurations, and correlating with melt-pool behaviour, microstructure, and mechanical performance. The core-only beam produced a highly concentrated heat source with limited melt-pool mixing, leading to Al accumulation (~2.7 wt.%), a high Fe(Al,Si) area fraction (~45%), and reduced linear joint strength of 211 ± 39 N/mm. The static core/ring beam did not significantly suppress Al enrichment or IMC formation due to the absence of temporal modulation. In contrast, the forward-triangle dynamic beam shape at 1428 kHz shape frequency promoted repeated beam traversal and enhanced melt-pool stirring, reducing Al content to ~1.3 wt.% and suppressing Fe(Al,Si) formation by ~78%. This was accompanied by martensitic refinement, increased low-angle grain boundary fraction, and improved hardness distribution. The forward-triangle beam shape achieved the highest linear joint strength (472 ± 26 N/mm) and weld efficiency (58%). Overall dynamic beam shaping effectively tailors melt-pool chemistry and solidification behaviour in overlap welds. Joint performance is governed by the combined effects of Fe-Al phase suppression and martensitic microstructural refinement enabled by dynamic beam modulation.

Contributing Authors

  • Mir-Hamza Khan
    University of Warwick
  • Tahir I Khan
    University of Bradford
  • Sharhid Jabar
    University of Warwick
  • Jeff Markus
    Multimatic Inc
  • Travis Stahler
    Multimatic Inc
  • Pasquale Franciosa
    University of Warwick
Mir-Hamza Khan
University of Warwick
Track: Laser Materials Macroprocessing
Session: TBD
Day of Week: Undetermined
Date/Time:
Location:

Keywords

  • Coherent Beam Combining
  • Fe-Al Intermetallics; Mechanical Properties
  • Laser Beam Welding
  • Mhz-Scale Dynamic Laser Beam Shaping
  • Ultra-High Strength Steel Boron Steel