Fiber laser welding of austenitic steel and commercially pure copper butt joint

The fiber laser welding of austenitic stainless steel and commercially pure copper in butt joint configuration without filler or intermediate material is presented. In order to melt stainless steel directly and melt copper via heat conduction a defocused laser beam was used with an offset to stainless steel. During mechanical tests the weld seam was more durable than heat affected zone of copper so samples without defects could be obtained. Three process variants of offset of the laser beam were applied. The following tests were conducted: tensile test of weldment, intermediate layer microhardness, optical metallography, study of the chemical composition of the intermediate layer, fractography. Measurements of electrical resistivity coefficients of stainless steel, copper and copper–stainless steel weldment were made, which can be interpreted or recalculated as the thermal conductivity coefficient. It shows that electrical resistivity coefficient of cooper–stainless steel weldment higher than that of stainless steel. The width of intermediate layer between stainless steel and commercially pure copper was 41–53 µm, microhardness was 128–170 HV_0.01.     

Experimental design approach to the process parameter optimization for laser welding of martensitic stainless steels in a constrained overlap configuration

This paper presents an experimental design approach to process parameter optimization for the laser welding of martensitic AISI 416 and AISI 440FSe stainless steels in a constrained overlap configuration in which outer shell was 0.55 mm thick. To determine the optimal laser-welding parameters, a set of mathematical models were developed relating welding parameters to each of the weld characteristics. These were validated both statistically and experimentally. The quality criteria set for the weld to determine optimal parameters were the minimization of weld width and the maximization of weld penetration depth, resistance length and shearing force. Laser power and welding speed in the range 855–930 W and 4.50–4.65 m/min, respectively, with a fiber diameter of 300 μm were identified as the optimal set of process parameters. However, the laser power and welding speed can be reduced to 800–840 W and increased to 4.75–5.37 m/min, respectively, to obtain stronger and better welds.     

Optimal design for a copper vapor laser with a maximum output by using a genetic algorithm

To obtain the maximum output of a copper vapor laser (CVL), 8 parameters of the CVL system including the length and radius of the laser tube, the peak voltage, the repetition frequency, the wall temperature and the LC parameters of the discharge circuit are optimized by using a genetic algorithm. The optimization has increased the laser power by 89% from primary 91 W (corresponding to the empirical configuration for the CVL system used in an experiment) to 172 W (the efficiency has also been increased from primary 1 to 1.16%).     

Measurement of the bead profile and microstructural characterization of a CO2 laser welded AISI 904 L super austenitic stainless steel

Laser welding of AISI 904 L super austenitic stainless steel using a diffusion cooled slab 3.5 kW CO₂ laser and employing two different shielding gases, namely argon and helium, was carried out. The laser weld bead profile depends on various parameters such as beam power (BP), travel speed (TS) and focal position (FP) of the laser spot. These parameters have to be selected suitably to obtain the desirable output. The cross sectioned area of the bead profiles measured using an optical microscope to determine the bead width and depth of penetration. X-ray diffraction used for phase identification confirmed that the weld structure was fully austenitic and dendritic. Hardness was observed to increase in the weld bead with respect to the parent metal and it was related to the microstructural refinement induced by a rapid cooling of the weld zone.     

Weld-bead profile and costs optimisation of the CO2 dissimilar laser welding process of low carbon steel and austenitic steel AISI316

The dissimilar full depth laser-butt welding of low carbon steel and austenitic steel AISI 316 was investigated using CW 1.5 kW CO₂ laser. The effect of laser power (1.1–1.43 kW), welding speed (25–75 cm/min) and focal point position (?0.8 to ?0.2 mm) on the weld-bead geometry (i.e. weld-bead area, A; upper width, W_u; lower width, W_l and middle width, W_m) and on the operating cost C was investigated using response surface methodology (RSM). The experimental plan was based on Box–Behnken design; linear and quadratic polynomial equations for predicting the weld-bead widthness references were developed. The results indicate that the proposed models predict the responses adequately within the limits of welding parameters being used. The regression equations were used to find optimum welding conditions for the desired geometric criteria.     

Dual beam method for laser welding of galvanized steel: Experimentation and prospects

Laser welding of zinc-coated steel sheets in lap configuration poses a challenging problem, because of the zinc vapours spoiling the quality of the weld. In continuation to the earlier work, the novel solution of dual laser beam method for lap welding of galvanized steel sheets is discussed here in view of the recently obtained observations and ensuing concerns. In this method the precursor beam cuts a slot, thus making an exit path for the zinc vapours, while the second beam performs the needed welding. The metallurgical analysis of the welds is encouraging showing absence of zinc in the welded area. In the current work on this technique, new experimental results have been obtained verifying the earlier observations. Along with this, the possibility of using a transversely split-up beam for the welding purposes with this approach is discussed and analyzed in this paper. This new technique is expected to be very useful in prospective industrial applications requiring higher welding throughput along with the needed quality.     

Optimal design of loudspeaker arrays for robust cross-talk cancellation using the Taguchi method and the genetic algorithm

An optimal design technique of loudspeaker arrays for cross-talk cancellation with application in three-dimensional audio is presented. An array focusing scheme is presented on the basis of the inverse propagation that relates the transducers to a set of chosen control points. Tikhonov regularization is employed in designing the inverse cancellation filters. An extensive analysis is conducted to explore the cancellation performance and robustness issues. To best compromise the performance and robustness of the cross-talk cancellation system, optimal configurations are obtained with the aid of the Taguchi method and the genetic algorithm (GA). The proposed systems are further justified by physical as well as subjective experiments. The results reveal that large number of loudspeakers, closely spaced configuration, and optimal control point design all contribute to the robustness of cross-talk cancellation systems (CCS) against head misalignment.     

Optimization of the operational parameters in a fast axial flow CW CO2 laser using artificial neural networks and genetic algorithms

This paper presents an artificial intelligence approach for optimization of the operational parameters such as gas pressure ratio and discharge current in a fast-axial-flow CW CO₂ laser by coupling artificial neural networks and genetic algorithm. First, a series of experiments were used as the learning data for artificial neural networks. The best-trained network was connected to genetic algorithm as a fitness function to find the optimum parameters. After the optimization, the calculated laser power increases by 33% and the measured value increases by 21% in an experiment as compared to a non-optimized case.     

Modeling and optimization of laser transmission joining process between PET and 316L stainless steel using response surface methodology

Laser joining parameters play a very significant role in determining the quality of laser transmission joining between PET films and 316L stainless steel plates. In the present work, Laser power, joining speed and stand-off-distance were considered as joining parameters. The parameters that influence the quality of laser transmission joining were optimized using response methodology for achieving good joint strength and minimal joint width. The central composite second-order Rotational Design (CCRD) has been utilized to plan the experiments and response surface methodology (RSM) is employed to develop mathematical relationships between joining parameters and desired responses. Based on the developed mathematical models, the interaction effects of the process parameters on laser transmission joining were investigated and optimum joining parameters were achieved. The experimental values nearly agree with the predicted values from mathematical models, indicates that the models can predict the responses adequately and optimize the key process parameters quickly.     

Optimal piezoelectric actuator and sensor location for active vibration control, using genetic algorithm

This paper deals with the optimization of piezoelectric actuators and sensors locations for active vibration control. Two modified optimization criteria are used, ensuring good observability or controllability of the structure, and considering residual modes to limit the spillover effect. Two optimization variables are considered for each piezoelectric device: the location of its center and its orientation. Genetic algorithms are used to find the optimal configurations. Several simulations are presented for a simply supported plate.     

Theoretical diagnostic and prediction of physical properties of quaternary InGaAsP compound using artificial neural networks optimized by the Levenberg Maquardt algorithm

The quaternaries \(In_{1 - x} Ga_{x} As_{y} P_{1 - y}\) are the main promising elements for the fabrication of optoelectronic devices. The adjustment of their physical parameters is assumed by the change of the molar fraction \(x\) and \(y\). These parameters can be affected by the variation of temperature and pressure. To make the theoretical diagnosis of these materials, it is fundamental to know the energy gap ‘\(\varvec{E}_{\varvec{g}}\)’ and the lattice parameter ‘\(a\)’, over a wide range of chemical compositions \(0 \le x \le 0.47\) and \(0 \le y \le 1\), at different temperatures and pressures. We show that by using the Artificial Neural Network method optimized by the Levenberg Maquardt algorithm ANN-LM, it is possible to obtain results very close to the experiment. The scatter plot and error calculation show that the ANN-LM model provides more accurate values of the lattice parameter than those calculated by Vegard’s law. On the other hand, the energy gap values \(Eg (x, y, T)\) estimated, using the ANN-LM model, proved to be close to the experimental values that those calculated by the empirical equations. In addition, the ANN-LM method allowed us to estimate with great accuracy the values of the energy gap at different temperatures and pressures \(Eg (P, T)\). Our work provides crucial information on the physical properties of the quaternary without the use of approximations, and without taking into account the hypothesis of a perfect agreement between \(InGaAsP\) and \(InP\) substrate.     

A fast method for the calculation of electron number density and temperature in laser-induced breakdown spectroscopy plasmas using artificial neural networks

A fast and precise method for the determination of electron temperature and electron number density in laser-induced plasmas is presented. The method is based on the use of a simple artificial neural network (ANN), trained on a suitable set of laser-induced breakdown spectroscopy spectra. The training procedure is quite fast; once the ANN is set, the determination of plasma temperature and electron number density is almost instantaneous, allowing the possibility of measuring these parameters, with good precision, in real time. A direct application of this new method could be the characterization of plasmas generated during pulsed laser deposition process of thin films and nanoparticles generation. The plasma electronic parameters will help to tune the energies involved in the stoichiometry and crystallization control of those nanostructured materials. As an example, the characteristics of the plasma induced by a Nd:YAG laser on a pure titanium target are determined, at different laser fluences.