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Optimization of electromagnetic steel lamination laser spot welding process parameters using response surface
Yi-Kai Huang1, Wei-Ling Chang1, Hsu-Hisen Chen1
1Department of Mechanical Engineering, National Cheng Kung University, No.1, University Road, Tainan, 701401, Taiwan.
Scientific Reports
|June 26, 2026
Summary
Laser spot welding optimizes electrical steel for transformers and motors, minimizing magnetic degradation. Optimized parameters and a ramp-down pulse shape significantly improve weld quality and stability.
Area of Science:
- Materials Science
- Manufacturing Engineering
Background:
- Electrical steel is vital for electric motors and transformers.
- Conventional welding methods cause magnetic degradation due to high heat input and wide heat-affected zones (HAZ).
- Laser spot welding offers precise energy control and reduced thermal impact for improved material properties.
Purpose of the Study:
- To investigate the effects of laser welding parameters on electrical steel.
- To optimize laser spot welding process for enhanced shear strength and weld spot cross-sectional area.
- To evaluate the impact of different pulse shapes on weld quality and stability.
Main Methods:
- Response Surface Methodology (RSM) with Central Composite Design (CCD) was used to study laser power, pulse width, and defocus distance.
- Analysis of Variance (ANOVA) confirmed the significance of process parameters.
- Regression models were developed and validated, with simplified models enhancing predictive accuracy.
Main Results:
- RSM models achieved high R2 values (0.88 for shear strength, 0.82 for cross-sectional area).
- Optimal process parameters were identified through RSM and confirmed experimentally.
- The ramp-down pulse shape effectively reduced thermal cracking and porosity, enhancing weld stability.
Conclusions:
- Laser spot welding is a viable method for processing electrical steel without magnetic degradation.
- Optimized parameters and specific pulse shapes (ramp-down) significantly improve weld quality.
- The study provides a framework for precise control and prediction of laser spot welding outcomes for electrical steel applications.
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