Analysis of laser welding process and porosity suppression based on controllable adjustment of energy and distribution

Analysis of laser welding process and porosity suppression based on controllable adjustment of energy and distribution | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Analysis of laser welding process and porosity suppression based on controllable adjustment of energy and distribution Yazhou Jia, Zipeng Yao, Yunjing Chen, Huixing Yan, Ruchuan Zeng, and 2 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7997689/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 5 You are reading this latest preprint version Abstract Unlike traditional continuous and pulsed lasers, in this study, the laser fixed-point and fixed-energy modulation of the molten pool is controlled by varying different energy elements. It can be obtained that the heat input is effectively reduced, the weld penetration is increased, and the porosity can be effectively reduced by 12.56% with the same value of total energy. By regulating different energy elements at the same location, the overall average temperature can be reduced, the molten depth can be increased, and the porosity can be decreased. Using a combination of large and small cyclic energies for regulation can effectively reduce heat input, achieving an overall maximum temperature reduction of 22.47 ℃. The most significant increase in molten depth was 13.21 µm at the three energies of 900W, 870W, and 840W combinations, and the porosity was reduced by 12.77%. By precisely controlling energy and distribution, the melt depth at each energy point can be greater than the reference value, and the porosity can be reduced across the entire range. The combination of 870w, 540w, and 330w is the optimal parameter set, which not only has the lowest porosity but also has a relatively large penetration depth. The experimental results indicate that by adjusting the size of different energy elements at various point distributions, and by regulating each point, line, and area in the weld seam, the heat input to the molten pool can be controlled. This results in welds that are aesthetically pleasing, have enhanced penetration, and exhibit low porosity. Variable energy element Heat input Porosity Controllable adjustment of energy and distribution Full Text Supplementary Files Highlight.docx Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 20 Jan, 2026 Reviewers invited by journal 18 Jan, 2026 Editor invited by journal 06 Nov, 2025 Editor assigned by journal 03 Nov, 2025 First submitted to journal 31 Oct, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7997689","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":576447981,"identity":"c3822819-078e-4260-9951-958195369076","order_by":0,"name":"Yazhou Jia","email":"","orcid":"","institution":"North China Institute of Aerospace Engineering","correspondingAuthor":false,"prefix":"","firstName":"Yazhou","middleName":"","lastName":"Jia","suffix":""},{"id":576447982,"identity":"f59a4ce3-e380-4c9b-8e09-b51ddeaef1d9","order_by":1,"name":"Zipeng Yao","email":"","orcid":"","institution":"North China Institute of Aerospace 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