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Article

Investigation of the Effects of Laser Welding Process Parameters on Weld Forming Quality Based on Orthogonal Experimental Design and Image Processing

by
Yuewei Ai
1,2,*,
Ning Sun
1,2,
Shibo Han
1,2,
Yang Zhang
1,2 and
Chang Lei
1,2
1
School of Traffic and Transportation Engineering, Central South University, Changsha 410075, China
2
Key Laboratory of Traffic Safety on Track of Ministry of Education, Central South University, Changsha 410075, China
*
Author to whom correspondence should be addressed.
Materials 2025, 18(15), 3627; https://doi.org/10.3390/ma18153627 (registering DOI)
Submission received: 27 August 2024 / Revised: 27 June 2025 / Accepted: 8 July 2025 / Published: 1 August 2025
(This article belongs to the Special Issue Advanced Computational Methods in Manufacturing Processes)

Abstract

Image processing has been widely adopted as an effective technology for analyzing weld forming quality which is greatly affected by the welding process parameters. In this paper, an L25(53) orthogonal experiment is designed to investigate the effects of welding process parameters on the weld forming quality in laser welding of aluminum alloy. The weld characteristics including the weld width (WW), weld penetration (PD), weld area (WA) and weld porosity (WP) under the conditions of the different welding process parameters consisting of the laser power (LP), welding speed (WS) and defocus distance (DD) are extracted from the laser welding experiment based on image processing. The effectiveness of the weld characteristics extraction method is verified by comparing the extracted results with the measured results. It is found that the WW, PD and WA are all significantly influenced by the LP among the three welding process parameters while the influences of the three process parameters on the WP are insignificant. The DD has a significant influence on the PD and the WS has a significant influence on the WA. The corresponding significance of influence is lower than the significance of influence of LP. The analysis results are conducive to the optimization of laser welding process parameters and improvement of welding quality.
Keywords: image processing; welding process parameters; weld forming quality; orthogonal experimental design; laser welding image processing; welding process parameters; weld forming quality; orthogonal experimental design; laser welding

Share and Cite

MDPI and ACS Style

Ai, Y.; Sun, N.; Han, S.; Zhang, Y.; Lei, C. Investigation of the Effects of Laser Welding Process Parameters on Weld Forming Quality Based on Orthogonal Experimental Design and Image Processing. Materials 2025, 18, 3627. https://doi.org/10.3390/ma18153627

AMA Style

Ai Y, Sun N, Han S, Zhang Y, Lei C. Investigation of the Effects of Laser Welding Process Parameters on Weld Forming Quality Based on Orthogonal Experimental Design and Image Processing. Materials. 2025; 18(15):3627. https://doi.org/10.3390/ma18153627

Chicago/Turabian Style

Ai, Yuewei, Ning Sun, Shibo Han, Yang Zhang, and Chang Lei. 2025. "Investigation of the Effects of Laser Welding Process Parameters on Weld Forming Quality Based on Orthogonal Experimental Design and Image Processing" Materials 18, no. 15: 3627. https://doi.org/10.3390/ma18153627

APA Style

Ai, Y., Sun, N., Han, S., Zhang, Y., & Lei, C. (2025). Investigation of the Effects of Laser Welding Process Parameters on Weld Forming Quality Based on Orthogonal Experimental Design and Image Processing. Materials, 18(15), 3627. https://doi.org/10.3390/ma18153627

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