In certain laser welding applications, it is desirable to achieve net-shape (weld bead flat to the parent material surface) welding and minimum geometry distortion. In this paper, an investigation is reported on factors affecting weld bead geometry and feasibility of achieving net shape welding for bead-on-plate welding of mild steel sheets with a 1 kW single mode fibre laser. Design of Experiments (DoE) and statistical modelling were used in the experimental study to understand parameter interactions. The selected independent process variables explored in this study are laser power and welding speed. The weld bead geometry characteristics were analysed and the conditions to achieve net-shape welding were determined.
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