A Multiscale and Multiphysics Framework for Laser Beam Welding with Dynamic Beam Shaping

Recent advances in dynamic beam shaping offer transformative potential for laser welding yet understanding of the process’s spatial and temporal response remains limited. This study employs a multi-kW continuous-wave laser with a coherent beam combiner and optical phased array to modulate fluence distribution at microsecond scales. Microstructural evolution is examined under individual and sequenced dynamic beam profiles operating in the kHz regime. Full-penetration bead-on-plate welds were performed on 1.5 mm AA6082 sheets using a self-restraint cantilever setup. Electron backscatter diffraction (EBSD) analysis revealed clear correlations between beam shapes and microstructure, highlighting both novel effects and emerging challenges for further research.