Process optimization and thermomechanical

simulation of residual stresses and

temperature distribution in the laser-beam
penetration welds of 61Ni-21Cr-9Mo alloy and
99.3Fe-0.45Mn-0.2C steel joints
Cite as: AIP Conference Proceedings 2281, 020033 (2020); https://doi.org/10.1063/5.0026223
Published Online: 15 October 2020

Shubham Sharma, Jujhar Singh, Vivek Aggarwal, Abhinav Sharma, Gursharan Singh, Shalab Sharma, and Munish
Mehta

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© 2020 Author(s).
 Process Optimization and Thermomechanical Simulation of
Residual Stresses and Temperature Distribution in the Laser-
Beam Penetration Welds of 61Ni-21Cr-9Mo Alloy
and 99.3Fe-0.45Mn-0.2C Steel Joints

Shubham Sharma1, a), Jujhar Singh1, b), Vivek Aggarwal1, Abhinav Sharma1,
Gursharan Singh1, Shalab Sharma2 and Munish Mehta3
1
Department of Mechanical Engineering, IKG Punjab Technical University, Jalandhar-Kapurthala Road,
Kapurthala, 144603, Punjab, India
2
Deptt. of Mechanical Engineering, DAV University, National Highway, Jalandhar - Pathankot Road, Jalandhar,
Punjab 144001, India
3
School of Mechanical Engineering, Lovely Professional University, Phagwara - 144411, Punjab, India

a)
Corresponding author: shubhamsharmacsirclri@gmail.com; shubham543sharma@gmail.co m
b)
jujharsingh2085@gmail.co m

Abstract. Laser welding is one of the important welding processes in industries for joining similar or different metals.
Demand of dissimilar metal welding has increased now a days from high performance, cost saving and efficiency point of
view. Various parameters like speed, beam power, spot diameter affect the quality, strength and cost of welding process.
In this paper the influence of speed, beam power and spot diameter over strength of welded specimen is studied using
Taguchi orthogonal array method. Two dissimilar metals such as 61Ni-21Cr-9M o alloy and 99.3Fe-0.45M n-0.2C steel is
welded using laser beam. The experiments are carried out as per Taguchi orthogonal array design matrix to predict
optimum process parameters Analysis of variance (ANOVA) is carried out to determine significantly affecting parameter
and the mathematical model to estimate ultimate tensile strength has been developed using Regression method. The
simulation of welding process to predict temperature distribution and residual stresses is predicted.
Keywords. Laser-beam welding; 61Ni-21Cr-9M o alloy; 99.3Fe-0.45M n-0.2C steel; Taguchi orthogonal array; Residual
stresses

1. INTRODUCTION
Laser welding is a welding process used to join two metals by the use of a laser source. The laser source provides a
concentrated and high-density heat source. The process is mostly used in high rate production industries, such as in
the automotive industry. The implementation of dissimilar metal combination provides flexibility of design so that
both metals can be used in efficient way. Laser welding is most efficient way of fusing dissimilar met als. Among all
the conventional method laser welding has its own advantages over quality and durability of welded joint.
61Ni-21Cr-9Mo alloy has high strength and has high oxidation and corrosion resistance. It has wide application in
high temperature and pressure zone like gas turbines. 61Ni-21Cr-9Mo alloy also has application in automotive
exhaust, nuclear plant and high-pressure vessels.
Process optimization is important technique for saving manufacturing time, cost of process and obtaining high
strength welded parts. Thus, Taguchi method is one of important process optimization technique which can be
implemented for laser parameters. The greatest advantages are saving experimental efforts, time, and cost and
finding significant factors very quickly.

Third International Conference on Inventive Material Science Applications

AIP Conf. Proc. 2281, 020033-1–020033-10; https://doi.org/10.1063/5.0026223
Published by AIP Publishing. 978-0-7354-4011-1/$30.00

020033-1
Temperature and residual stresses are important parameters which affects the strength and quality of welding. It is
also used to study thermo-mechanical behavior of welded joints.

FIGURE 1. Laser welding with different process parameters

The evolution of thermo-mechanical, microstructure and its properties due to welding depends on several factors.
Some factors include the parameters of the welding process, base-metal, percent-weight composition, tool geometry,
tool material etc. The influence of process parameters on the mechanical properties, thermal-ageing properties,
material-flow, temperature-history distribution and microstructural studies for various materials were extensively
reported in the literature. Rhodes et al. (1997) joined AA7075 plates using FSW at a 5 min/min welding rate and
studied changes in alloy microstructure due to FSW. It is noted that the nugget is recrystallized, the displacement
density was reduced, and it was found that the cure precipitations were resolved. Mahoney et al. (1998b) studied the
effect of FSW and subsequent thermal aging on the longitudinal and transverse properties of 7075T651.
Lockwood et al. (2002) reported that transitions from TMAZ to HAZ and HAZ to base material for AA 2024 are
gradually. The areas did not differ from a sharp change microstructure. Sato et al. (2002), aluminum alloy 6063
friction welded to temperature T4 and T5 at different rotational speeds. Increase in the rotational speed caused an
increase in the maximum welding temperature which resulted in an exponential increase in the size of the granules.
6063-T5 showed a reducing the hardness around the welding center, while the hardness was homogeneous for 6063-
T4. The increase in hardness due to aging after welding was small in the shaking area of weld s produced at low
speeds due to rotation increasing the volume fraction of PFZ. Peel et al. (2003) fused AA5083 welded alloys under
different conditions.
Cabibbo et al. (2007) reported fine and recrystallized cereals structure due to the mixing and forging of the Alloy
6056 female FSW. Nugget has very refined grains and a balanced grain structure with a lot of it a distinct transition
in granule size on the advanced and retracted side. Sutton et al., (2004) also reported a very good size of the upper
surface granules of the nugget in which the contact with the instrumental shoulder arose.
Boz and Kurt (2004) investigated the effect of agitator geometry on FSW aluminum AA1080. Five different stirrers,
one square geometry and the other with cylindrical geometries with another screw on the screw they were used.
Binding was better with square, but mechanical and metallographic properties were poor due to a large mass transfer
of traction fractures occurred in the base metal and an UMP of 110 MPa was achieved with shaking of 0.85 and 1.1
mm screws. Lim et al (2004) examined the effect of TRS and WS on traction FSM alloy behavior 4 mm thick
AA6061-T651. The plates were friction mix high-speed welding of 1000, 1400, 1600, 2000 and 2500 rpm gears, and
welding speeds of 0.1, 0.2, 0.3 and 0.4 m/min. Resistance to yield, final tensile strength and traction elongation have
been affected by parameters, with elongation decreases with WS decrease and TRS increase. Group of coarse
precipitates of Mg2Si due to the action of motion and biting through the serious plastic flow in the welding area was
the cause of the traction behavior. Low WS and high TRS encourage plastic flow and therefore clustering
precipitate. Chen et al. (2005) reported a significant improvement in traction t he strength of the FSW joints of the

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2219-O aluminum alloy through a welding posture thermal treatment (PWHT). PWHT joints were broken into wire
area. Zhao et al (2005) investigated the effect of tool pocket geometry on the welding structure and the mechan ical
properties of the aluminum alloy AA2014 using different pin geometries. The flow of plastic differs for different
pins geometry. Microscopic examination of the welding area and tests on mechanical properties have shown that
bolts with inclined screws has produced the best link. The appearance of the weld was not obvious defects. The
welding nugget cereals were very fine with a fine distribution of precipitate.
Tang et al (1998) measured experimental temperature data for FSW of AA6061-T6 and concluded that the
generation of heat in the FSW was mainly due to friction at the instrument's shoulder. Li et al (1999) reported
metallographic flux patterns cross sections in friction mixing welds made between different aluminum alloys
2024/6061 using differential grading. The presence of the complex vortex, whorl and the characteristic turbulence
characteristics of the chaotic-dynamic mixture have been reported. Seidel and Reynolds (2001) and Reynolds
Reynolds (2000) analyzed the flow of material in AA 2195-T8 friction welds, based on a post welding determination
of the position of AA5454-H32 markers placed in welding surface. Full 3D display of distorted markers was
obtained from the material positions before and after welding in thermo -mechanically affected areas by a serial
cutting technique.
The Analytical and numerical modeling of heat transfer and material flow in FSW was made using Lagrangean,
Eulerian, or Lagrangean Eulerian Arbitrary approaches. The results of these models were validated by experimental
data. The heat the transfer and distribution of temperature in the work piece have been proven to be asymmetric due
to asymmetry in stretch velocity and viscous dissipation. Material the flow was found dependent on the material
contact with the instrument. Heurtier et al (2002) used an analytical model to predict the work piece temperatures.
Heurtier. P et.al (2006) proposed a semi-analytic thermal mechanical model based on speed fields to obtain strains,
stem rates and temperature estimates and micro-hardness in different welding areas. The micro hardness profile was
derived from thermal history and denoted the homogeneity of the weld that can be reduced by reducing the average
temperature by increasing tool speed. The pattern also predicted the weakened welding area due to the distribution
of oxide after welding process.
In Solid mechanics Based Modeling, the main principle of the Lagrangean model is to analyze the FSW process in
Solid Computational Mechanics. With this approach, thermomechanical modeling and residual analysis can be
performed efficiently. With particle tracking, the flow of material during FSW can also be analyzed. Gould and
Feng (1998) have developed a simple model of heat flow relates the variation of the temperature field to the welding
parameters. The pattern which uses the heat source used by Rosenthal (1938) and Rosenthal (1941) considered only
friction heating by the shoulder. Many simplification assumptions were used to obtain a solution in closed form for
result. Chao and Qi (1998) have developed the first 3-D thermal and thermal mechanical model for FSW based on
FEM. Generation of heat due the friction contact between the instrument shoulder and the work piece was only
taken into account. The model uses thermal convection and temperatu re dependence properties of materials. The
model includes the support plate and low yield stress was used for the nugget. Total heat input to welding and heat
the bottom transfer was repeated in a test and error mode, until predicted temperatures are match ed with validation
experiments. Post welding Residual resistance and distortion could be predicted using the calculated calculation
temperature distribution. The model considered the heat of friction generated between the shoulder and the
workpiece and the effect of the tool pin was not taken into account in the model.
Modeling material flow in FSW using models to consider the flow of materials is a recent research area. There are
two essential elements approaches in shaping the material flow, namely, the Eulerian approach and Arbitrary
Lagrangean Eulerian (ALE). In the Eulerian approach, deformed plastic material is treated as a very viscous fluid
and Dynamics of Computational Fluids (CFD) is used to obtain the flow field. In the ALE, solid mechanics are u sed
for the analysis of plastic deformation and a displacement field is found using the finite volume method.
Eulerian models are based on CFD, the results obtained by solving the continuity, impulse and energy equation for
obtaining the necessary results . The CFD method is convenient for temperature estimation distribution and flow of
materials. The method has the advantage that the particle tracking is not required, as with the Lagrangean method, as
a material flowing through the field. Colegrove and Shercliff (2004) analyzed material flow during FSW of the
AA7075 model using a CFD-based model. The model was applied to analyze material flow around the Trivex and
MX-Trivex tools. The results were compared to Triflu's analysis. Result from the analysis indicates that the
transverse and downward forces have been reduced by The Trivex tool. Lines around the instruments were used to
examine the material flow. It has been found that the downward force increases with the Triflu tool. The strong
action of augmentation of the trifal instrument caused this increase. Reynolds et al (2005) used the thermal welding
simulation to provide time-temperature for a series of aluminum alloy welds 7050-T7. Heating and cooling rate

020033-3
during FSW of the 7050-aluminum alloy was affected by WS. Temperatures during FSW correlated well with
welding power and peak temperature was a complex function of TRS and WS. The maximum hardness of the
nugget corresponds to the highest welding temperature. Colegrove and Shercliff H.R. (2005) analyzed the three flow
of dimensional material and temperature around a threaded tool by variation the rotation speed and the tool angle of
inclination. The model predicted size and distribution of the deformation zone temperature as dipping the material
that is above the solid temperature and the slip between the tool and the interface were not incorporated into the
model. Cho et. al., (2005) developed a heat of two stationary sizes transfer and material flow model for FSW
stainless steel 304 L. Thus, the key objectives of this research work were written as mentioned below:
i. Selection of process parameters and their effect on dissimilar metal joints.
ii. To optimize laser welding process parameters to obtain maximum weld strength.
iii. Development of mathematical model to predict weld strength using regression analysis.
iv. Comparison experimental results of strength results with mathematical model develop.
v. Thermo-mechanical modeling of laser welding process to predict temperature distribution and residual
stresses.

2. EXPERIMENTATION
2.1 Materials and Methods

2.1.1 Material Specification

99.3Fe-0.45Mn-0.2C alloy and 61Ni-21Cr-9Mo steel plates are joined together with CO2 laser welding process.
61Ni-21Cr-9Mo alloy is Nickel-chromium-Molybdenum based metal generally referred as Nickel alloy. It has 21%
of chromium, 61% Nickel, 9% molybdenum and remaining is carbon, sulfur and iron. While 99.3Fe -0.45Mn-0.2C
steel is a carbon steel containing 0.2% carbon and Iron as major constitute.

TABLE 1. Process parameters and their levels

Factors Level 1 Level 2 Level 3

Welding Speed (mm/s) 2 4 6
Beam Power (W) 900 1200 1500
Spot Diameter (mm) 0.4 0.6 0.8

Both the materials, 99.3Fe-0.45Mn-0.2C alloy and 61Ni-21Cr-9Mo steel-based plates were prepared with
dimensions of 160×65×0.84 mm3 . Both the plates are welded in width direction using laser beam. The gap between
two plates is 0.02 mm. Nine plates are welded with different pro cess parameters using Taguchi orthogonal array
table 2.

TABLE 2. Design-M atrix layout using L9 Taguchi Orthogonal array

Experimental Trial Run Welding S peed (mm/s) Beam Power (W) S pot Diameter (mm)

1 1 1 1
2 2 2 1
3 3 3 1
4 1 2 2
5 2 3 2
6 3 1 2
7 1 3 3
8 2 1 3
9 3 2 3

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Out of welded plates, specimens are cut by laser for tensile test. The dimensions of tensile test specimen are shown
in figure. Same procedure is conducted for nine welded plates. The ultimate tensile strength along with process
parameters are shown in table 3.

(a). Dum-bell shaped welded specimen before Tensile-test

(b). Dum-bell shaped welded specimen after Tensile-test

FIGURE 2(a-b). Specimens before and after tensile test

TABLE 3. Parameters and response of tensile test

Laser beam Power S pot Diameter Tensile

S .No. Welding (W) (mm) S trength S /N ratio Mean
speed (mm/s) (MPa)
1 2 900 0.4 353.17 50.90 353.17
2 4 1200 0.4 344.12 50.70 344.12
3 6 1500 0.4 422.27 52.46 422.27
4 2 1200 0.6 417.20 52.36 417.20
5 4 1500 0.6 423.57 52.49 423.57
6 6 900 0.6 312.98 49.85 312.98
7 2 1500 0.8 461.57 53.24 461.57
8 4 900 0.8 337.34 50.56 337.34
9 6 1200 0.8 327.47 50.24 327.47

3. RESULTS AND DISCUSSIONS

3.1 Taguchi Method

3.1.1 Analysis of Signal to Noise Ratio (S/N)

Taguchi S/N ratio is logarithmic function of output as its objective function of optimization. S/N takes both mean
and the variables into account. There are three quality characteristics for Taguchi method as follows:
i.

ii. ∑

iii. ∑

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For our process parametric optimization, we use larger is best.

TABLE 4. Analysis of signal to noise ratio

Levels Weld-speed (mm/s) Laser beam power (W) S pot Diameter
(mm)
1 52.29 50.54 51.48
2 51.35 51.22 51.69
3 50.98 52.87 51.45
Delta 1.44 2.43 0.36
Rank 2 1 3

FIGURE 3. S/N ratio of different parameters

Based upon S/N ratio, welding process parameter with greater tensile strength is obtained at welding speed at Level
1, Beam power at Level 3 and spot diameter at level 2. Table 5 shows optimum process parameters for greater
strength.

TABLE 5. Optimum process parameters

Weld-speed Laser beam S pot
(mm/s) Power (W) Diameter (mm)
2 1500 0.6

3.1.2 Regression Analysis

Weld speed, power and spot diameter are considered for development of mathematical model. Correlation between
these parameters is obtained by multiple regression method. In this method, coefficient of regression (R 2 ) should be
greater than 90% for fit experiment.

Using Minitab, the regression equation obtained is,

020033-6
Thus, the Coefficient of regression founds out to be 89.9%. The Tensile strength value as computed from the
equation is 456.66 MPa and Experimental tensile test value came out to be 451.96 MPa.

3.1.3 Analysis of Variance (ANOVA)

Analysis of variance is used to obtain maximum contribution of process parameter for maximu m tensile strength.

TABLE 6. Percentage contribution of parameters using ANOVA

S ource DOF S um of Mean F- P- Percentage
square S quare ratio ratio contribution
Weld-speed 2 4772.6 2386.3 9.46 0.028 21.02
Laser beam power 2 15394.6 7697.3 30.52 0.003 67.83

Spot diameter 2 5.8 2.9 0.01 0.918 0.025

Residual Error 2 2522.2 1261.1 - - 11.11

Total 8 22695.1 100

From the above table, the percentage contribution of beam power is more (67%) than other process parameters for
obtaining maximu m tensile strength.

3.1.4 Temperature Distribution

Using optimum process parameters, simulation is made in Simufact Welding software. The temperature distribution
is shown in fig.4.

FIGURE 4. Temperature distribution at time 4 seconds

FIGURE 5. Temperature distribution at time 10 seconds

Nine points are considered as shown in fig.4. The centerline or welding line is considered at y=0 mm at interval of
5mm from center line remaining tracking points are considered along both sides.
The variation of temperature against time graph is shown in fig.6. Since y=0 is at heat source zone, the temperature
reaches very high as shown in figure. At y=5mm and y=10mm the peak temperature goes on decreasing.

020033-7
 FIGURE 6. Variation of temperature with time along track points

From figure 6, it can be observed that as distance increases from weld zone, the time required to reach peak
temperature also increases.

3.1.5 Residual Stress

The residual stressed induced due to laser welding is show in fig.7. The maximum value of residual stress induced is
344.84 MPa.

FIGURE 7. Residual stress induced in specimen

4. CONCLUSIONS

The process parameters are optimized for maximum tensile strength of welded specimen using Taguchi orthogonal
array. S/N ratio shows the optimum process parameters are weld -speed of 2 mm/s, Laser beam power of 1500 W
and spot-diameter of 0.6 mm. Regression equation is obtained and the maximum strength value is 456.66 MPa and
is verified experimentally with value of 451.96 MPa. The temperature and stresses induced in specimen is predicted.
The temperature contours and temperature cycle at different locations is predicted. Simulation shows maximum
residual stress induced is 344.84 MPa.

020033-8
 5. FUTURE OUTLOOK
Experimental validation of temperature distribution can verify using either thermocouple or temperature gun. The
residual stresses induced can be verified using X-ray diffraction machine.
Declaration of conflict of Interest:
The authors declare that they have no conflict of interest with respect to the research, authorship, and/or publication
of this article.
Funding:
The authors doesn’t receive any research fund or grant from any organization.
Ethical approval:
This article does not contain any studies with human participants or animals performed by the author.
Acknowledgements:
The authors wish to acknowledge the Department of RIC, IK Gujral Punjab Technical University, Kapurthala,
Punjab, India.

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