Microstructural Evolution and Mechanical Performance of Dual-Phase Steels under Fiber Laser Welding: Effects of Heat Input and Weld Penetration

This study investigates the effects of fiber laser welding (FLW) parameters on the microstructural evolution and mechanical properties of DP800, DP1000, and DP1200 dual-phase steels, focusing on the role of heat input. Welding was performed using laser powers ranging from 1500 to 3000 W and welding speeds between 20 and 100 mm/s, resulting in heat inputs from 18 to 120 J/mm. Optimal welding conditions were identified as 55 J/mm for DP800, 120 J/mm for DP1000, and 53 J/mm for DP1200, which ensured full penetration and minimized HAZ softening. Detailed microstructural analysis using SEM and EBSD revealed significant transformations in the heat-affected zone (HAZ), including martensite degradation, grain coarsening, and tempered martensite formation, particularly in DP1200 steel, where hardness reductions reached up to 29%. Tensile tests demonstrated that while DP800 and DP1000 joints primarily failed within the base material (BM) with ductile fracture characteristics, DP1200 joints fractured within the HAZ due to a combination of brittle cleavage and ductile dimples caused by martensite breakdown and carbide precipitation. The findings underscore the necessity of optimizing welding parameters to control HAZ softening and preserve mechanical performance. By systematically analyzing the interplay between heat input, microstructure, and mechanical properties across different DP steel grades, this research provides a comprehensive understanding of how FLW conditions influence joint integrity, offering valuable guidance for designing robust welding strategies in advanced engineering applications.