Correlating Microstructural and Mechanical Property Alteration with Process Parameters Using Thermal Signature Monitoring of Laser-Welded Inconel 625 Superalloy

Inconel 625 is widely employed in high-temperature and corrosive environments, where the integrity of welded joints critically influences component performance. This study systematically investigates how laser beam welding (LBW) heat input governs cooling behaviour, microstructure evolution, elemental segregation, and the mechanical performance of Inconel 625 weld joints aiming to become sustainable joints. A single-spot monochromatic non-contact type infrared pyrometer is used to monitor the thermal cycles of the molten weld pool and the cooling rate and melt pool lifetime were determined based on the thermal cycle data. The impact of cooling rate and melt pool lifetime on weld geometry, microstructure, micro-segregation, and mechanical properties were thoroughly investigated. The findings revealed that the fibre laser welding produced sound, defect-free joints across all experimental heat-input conditions and the weld quality was fairly dictated by cooling rate during solidification. Reducing heat input (by using faster laser scan speeds) increased the cooling rate (1.45 × 103 to 3.65 × 103 °C/s), resulting in a shortened melt-pool lifetime and altered weld bead geometry from hourglass to truncated-cone profiles. Eventually, the fusion-zone microstructure transitioned from coarse cellular/columnar dendrites at high heat inputs to refined dendrites at low heat inputs. The EDS analysis revealed pronounced Nb and Mo segregation in slowly cooled welds and Laves phase formation due to insufficient time for solute redistribution and γ-Ni matrixes were consistent noted with XRD-observed peaks. The presence of the brittle Laves phase adversely affects the microhardness and tensile strength of the weld joints. Mechanical testing confirmed that decreasing heat input (in faster laser scan speeds) enhanced micro-hardness and tensile strength due to grain refinement and solute entrapment in the γ matrix. The highest joint strength (989.3 ± 10.4 MPa) and elongation (40.3 ± 1.8%) approached those of the work material, and these findings establish processing parameter–structure–property relationships for the LBW of Inconel 625. The co-relation in the present manuscript can be used in the future for process monitoring and for controlling the mechanical properties of laser welding and may provide a practical guidance for optimizing weld quality in advanced industrial applications.