Influence of Laser Beam Orientation on Weld Morphology, Microstructure, and Mechanical Performance of Similar and Dissimilar Dual-Phase Steels: A Comprehensive Review

Abstract This review encompasses a comprehensive evaluation of the findings from various experimental works and computational data on welding dual-phase steel in similar and dissimilar configuration. It concentrates on the effect of the orientation of laser beam on geometrical features of the weld joint, microstructure, defect occurrence, and mechanical behavior of dual-phase steel. These steels, characterised by a ferritic matrix with islands of martensite, are among the most preferred Advanced High-Strength Steels due to their exceptional strength, formability, and crashworthiness. The automotive industry uses laser-based processing for dual-phase (DP) steels because of their high precision, adaptability, and suitability for lightweight design specifications. Laser incidence angle is considered as crucial factors for establishing melting pool dynamics, penetration depth, heat input and, stress field, joint strength and hardness uniformity, and fatigue lifetime. Experimental investigations prove the efficiency of the application of tilting angle in the range of 5° to 15° degrees in achieving successful results in balancing welding with the lowest number of defects. Numerical techniques, help in acquiring thermal cycle, key hole stability, and phase transformation kinetics data. This study aims to highlights some of the unresolved research areas, industrial applications, and future prospects of laser beam orientation adaptation.