{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,11,3]],"date-time":"2026-11-03T13:02:55Z","timestamp":1793710975853,"version":"4.6.1"},"reference-count":42,"publisher":"Springer Science and Business Media LLC","issue":"1","license":[{"start":{"date-parts":[[2026,2,26]],"date-time":"2026-02-26T00:00:00Z","timestamp":1772064000000},"content-version":"tdm","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0"},{"start":{"date-parts":[[2026,2,27]],"date-time":"2026-02-27T00:00:00Z","timestamp":1772150400000},"content-version":"vor","delay-in-days":1,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0"}],"funder":[{"DOI":"10.13039\/501100003509","name":"\u00d6rebro University","doi-asserted-by":"crossref","id":[{"id":"10.13039\/501100003509","id-type":"DOI","asserted-by":"crossref"}]}],"content-domain":{"domain":["link.springer.com"],"crossmark-restriction":false},"short-container-title":["Sci Rep"],"abstract":"<jats:title>Abstract<\/jats:title>\n                  <jats:p>\n                    Aluminum alloy AA8011 is widely utilized in automotive and lightweight engineering applications, although traditional fusion welding frequently produces faults due to its high thermal conductivity and restricted weldability. This work investigates High Power Diode Laser Beam Welding (HPDLBW) of 2\u00a0mm AA8011 sheets employing laser power (3.2\u20133.4\u00a0kW), welding speed (17\u201323\u00a0mm\/s), shielding gas (20 L\/min) and beam diameter (3\u20134\u00a0mm) built with a Taguchi L9 orthogonal array. A response surface model linked process factors to mechanical responses, including impact energy, hardness, and tensile strength. Optimal settings for multi-objective optimization (P\u2009=\u20093.3\u00a0kW, v\u2009=\u200917\u00a0mm\/s, d\u2009=\u20093.5\u00a0mm) resulted in 110\u00a0J of impact energy, 33 HV0.5 of hardness, and 69 N\/mm\n                    <jats:sup>2<\/jats:sup>\n                    of tensile strength. Analysis of variance revealed that laser power accounted for up to 38.6% of the variation in weld penetration, confirms its prominent role in melt pool development, while tensile strength improved by a maximum of 14.2% under optimal conditions. Under optimum conditions, microstructural research revealed refined fusion zones, minimized intermetallic formation, and little porosity. The work shows that Taguchi-based modeling and optimization give a predictive framework for enhancing AA8011 weld performance, and it establishes HPDLBW as a dependable method for lightweight alloy joining. The study demonstrates HPDLBW as a viable and scalable joining technology for lightweight aluminum structures, with lower heat input, improved surface polish, and practical significance for the automotive and packing industries.\n                  <\/jats:p>","DOI":"10.1038\/s41598-026-41272-1","type":"journal-article","created":{"date-parts":[[2026,2,26]],"date-time":"2026-02-26T02:45:17Z","timestamp":1772073917000},"update-policy":"https:\/\/doi.org\/10.1007\/springer_crossmark_policy","source":"Crossref","is-referenced-by-count":3,"title":["High power diode laser beam welding of AA8011 aluminum alloy for enhanced mechanical performance in lightweight structures"],"prefix":"10.1038","volume":"16","author":[{"ORCID":"https:\/\/orcid.org\/0000-0001-6869-7180","authenticated-orcid":false,"given":"Rajesh","family":"Patil","sequence":"first","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-2014-1308","authenticated-orcid":false,"given":"Magnus","family":"L\u00f6fstrand","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"297","published-online":{"date-parts":[[2026,2,26]]},"reference":[{"key":"41272_CR1","doi-asserted-by":"publisher","first-page":"446","DOI":"10.4028\/www.scientific.net\/AMM.813-814.446","volume":"813\u2013814","author":"K Palani","year":"2015","unstructured":"Palani, K. & Elanchezhian, C. Multi-response optimization of process parameters on AA8011 friction stir welded aluminum alloys using RSM based GRA coupled with DEA. Appl. Mech. Mater. 813\u2013814, 446\u2013450 (2015).","journal-title":"Appl. Mech. Mater."},{"key":"41272_CR2","first-page":"260","volume":"71","author":"G Chakravarthi","year":"2022","unstructured":"Chakravarthi, G. et al. Investigation on the effect of process parameters on mechanical and microstructural properties of AA8011 similar FSW weld joints. J. Manuf. Process. 71, 260\u2013273 (2022).","journal-title":"J. Manuf. Process."},{"key":"41272_CR3","doi-asserted-by":"crossref","unstructured":"Elanchezhian, C., Vijaya Ramnath, B., Venkatesan, P., Sathish, S., Vignesh, T., Siddharth, R. V., Vinay, B. & Gopinath, K. Parameter optimization of friction stir welding of AA8011\u20136062 using mathematical method. In Proc. 12th Global Congress on Manufacturing & Management (GCMM), 2014.","DOI":"10.1016\/j.proeng.2014.12.308"},{"key":"41272_CR4","doi-asserted-by":"publisher","first-page":"807","DOI":"10.1108\/WJE-01-2023-0029","volume":"21","author":"SN Lonavath","year":"2024","unstructured":"Lonavath, S. N. & Boda, H. Characterization and optimization of weld properties due to the effect of different pin profiles for AA8011-based friction stir welding. World J. Eng. 21, 807\u2013820 (2024).","journal-title":"World J. Eng."},{"key":"41272_CR5","doi-asserted-by":"publisher","first-page":"3891","DOI":"10.1007\/s12633-024-02961-6","volume":"16","author":"IJ Singh","year":"2024","unstructured":"Singh, I. J. Effect of welding speed on metallurgical characterization and mechanical properties in CMT\/other fusion welding of dissimilar AA6061\u2013AA8011. SILICON 16, 3891\u20133903 (2024).","journal-title":"SILICON"},{"key":"41272_CR6","doi-asserted-by":"publisher","first-page":"365","DOI":"10.1023\/A:1021901715578","volume":"44","author":"N Fridlyander","year":"2002","unstructured":"Fridlyander, N. et al. Aluminum alloys: Promising materials in the automotive industry. Met. Sci. Heat Treat. 44, 365\u2013370 (2002).","journal-title":"Met. Sci. Heat Treat."},{"key":"41272_CR7","first-page":"22","volume":"28","author":"T Sakurai","year":"2008","unstructured":"Sakurai, T. The latest trends in aluminum alloy sheets for automotive body panels. Kobelco Technol. Rev. 28, 22\u201328 (2008).","journal-title":"Kobelco Technol. Rev."},{"key":"41272_CR8","doi-asserted-by":"publisher","first-page":"33","DOI":"10.4028\/www.scientific.net\/MSF.242.33","volume":"242","author":"J Hirsch","year":"1997","unstructured":"Hirsch, J. Aluminum alloys for automotive application. Mater. Sci. Forum 242, 33\u201350 (1997).","journal-title":"Mater. Sci. Forum"},{"key":"41272_CR9","doi-asserted-by":"publisher","first-page":"862","DOI":"10.1016\/j.matdes.2013.12.002","volume":"56","author":"T Dursun","year":"2014","unstructured":"Dursun, T. & Soutis, C. Recent developments in advanced aircraft aluminum alloys. Mater. Des. 56, 862\u2013871 (2014).","journal-title":"Mater. Des."},{"key":"41272_CR10","doi-asserted-by":"publisher","first-page":"5775","DOI":"10.1016\/j.actamat.2003.08.023","volume":"51","author":"JC Williams","year":"2003","unstructured":"Williams, J. C. & Starke, E. A. Progress in structural materials for aerospace systems. Acta Mater. 51, 5775\u20135799 (2003).","journal-title":"Acta Mater."},{"key":"41272_CR11","doi-asserted-by":"publisher","first-page":"577","DOI":"10.1016\/j.jallcom.2016.12.269","volume":"698","author":"J Shin","year":"2017","unstructured":"Shin, J., Kim, T., Kim, D., Kim, D. & Kim, K. Castability and mechanical properties of new 7xxx aluminum alloys for automotive chassis\/body applications. J. Alloys Compd. 698, 577\u2013590 (2017).","journal-title":"J. Alloys Compd."},{"key":"41272_CR12","doi-asserted-by":"publisher","first-page":"1995","DOI":"10.1016\/S1003-6326(14)63305-7","volume":"24","author":"J Hirsch","year":"2014","unstructured":"Hirsch, J. Recent development in aluminum for automotive applications. Trans. Nonferrous Met. Soc. China 24, 1995\u20132002 (2014).","journal-title":"Trans. Nonferrous Met. Soc. China"},{"key":"41272_CR13","doi-asserted-by":"publisher","first-page":"5015","DOI":"10.1016\/j.matpr.2015.10.091","volume":"2","author":"J Zhou","year":"2015","unstructured":"Zhou, J., Wan, X. & Li, Y. Advanced aluminum products and manufacturing technologies applied on vehicles presented at the Euro Car Body conference. Mater. Today Proc. 2, 5015\u20135022 (2015).","journal-title":"Mater. Today Proc."},{"key":"41272_CR14","first-page":"172","volume":"2","author":"A Kumar","year":"2016","unstructured":"Kumar, A. & Milton, M. S. A comparison of welding techniques of aluminum alloys: A literature review. Int. J. Sci. Res. Sci. Eng. Technol. 2, 172\u2013175 (2016).","journal-title":"Int. J. Sci. Res. Sci. Eng. Technol."},{"key":"41272_CR15","first-page":"383","volume":"44","author":"R Rajan","year":"2016","unstructured":"Rajan, R., Kah, P., Mvola, B. & Martikainen, J. Trends in aluminum alloy development and their joining methods. Rev. Adv. Mater. Sci. 44, 383\u2013397 (2016).","journal-title":"Rev. Adv. Mater. Sci."},{"key":"41272_CR16","doi-asserted-by":"publisher","first-page":"50","DOI":"10.1016\/j.matdes.2015.03.064","volume":"77","author":"O Ola","year":"2015","unstructured":"Ola, O. & Doern, F. Fusion weldability studies in aerospace AA7075-T651 using high-power continuous wave laser beam techniques. Mater. Des. 77, 50\u201358 (2015).","journal-title":"Mater. Des."},{"key":"41272_CR17","doi-asserted-by":"crossref","unstructured":"Cross, C. E., Olson, D. L. & Liu, S. Aluminum Welding. In Handbook of Aluminum, vol. 1, 1\u201336 (Dekker, 2003).","DOI":"10.1201\/9780203912591.ch9"},{"key":"41272_CR18","doi-asserted-by":"publisher","first-page":"1851","DOI":"10.1007\/s00170-016-9861-0","volume":"91","author":"G Cam","year":"2017","unstructured":"Cam, G. & Ipekoglu, G. Recent developments in joining of aluminum alloys. Int. J. Adv. Manuf. Technol. 91, 1851\u20131866 (2017).","journal-title":"Int. J. Adv. Manuf. Technol."},{"key":"41272_CR19","doi-asserted-by":"publisher","first-page":"239","DOI":"10.4028\/www.scientific.net\/MSF.818.239","volume":"818","author":"J Vinas","year":"2015","unstructured":"Vinas, J. & Abel, M. Analysis of laser welds on automotive steel sheets. Mater. Sci. Forum 818, 239\u2013242 (2015).","journal-title":"Mater. Sci. Forum"},{"key":"41272_CR20","doi-asserted-by":"publisher","first-page":"238","DOI":"10.1179\/095066099101528298","volume":"44","author":"H Zhao","year":"1999","unstructured":"Zhao, H., White, D. R. & Debroy, T. Current issues and problems in laser welding of automotive aluminum alloys. Int. Mater. Rev. 44, 238\u2013266 (1999).","journal-title":"Int. Mater. Rev."},{"key":"41272_CR21","unstructured":"Laser line GmbH. Laser welding aluminum: Aluminum welding of visible surfaces. Laser line 1\u20132, (2025)."},{"key":"41272_CR22","unstructured":"Zediker, M. S. (Ed.) High-Power Diode Laser Technology XXII, Proceedings of SPIE, vol. 12867, San Francisco, CA, 2024."},{"key":"41272_CR23","unstructured":"Blothe M., et al. Direct Ultrafast Laser Welding of Transparent to Non-Transparent. Proc. of Lasers and Processes for Digital Manufacturing Technology, 10\u201316 (2024)."},{"key":"41272_CR24","doi-asserted-by":"publisher","first-page":"301","DOI":"10.1016\/j.jmatprotec.2016.06.021","volume":"237","author":"H Zhang","year":"2016","unstructured":"Zhang, H. et al. Microstructure and mechanical properties of laser beam-welded AA2060 Al\u2013Li alloy. J. Mater. Process. Technol. 237, 301\u2013308 (2016).","journal-title":"J. Mater. Process. Technol."},{"key":"41272_CR25","doi-asserted-by":"crossref","unstructured":"Li, Z., et al. Study of thermal behavior and solidification characteristics during laser welding of dissimilar metals. Results in Physics. 12, 1062\u20131072 (2021).","DOI":"10.1016\/j.rinp.2018.12.017"},{"key":"41272_CR26","doi-asserted-by":"publisher","first-page":"121","DOI":"10.1016\/j.jmatprotec.2017.04.002","volume":"247","author":"S Meco","year":"2017","unstructured":"Meco, S., Ganguly, S. & Williams, S. Laser welding of steel to aluminum: Thermal modelling and joint strength analysis. J. Mater. Process. Technol. 247, 121\u2013133 (2017).","journal-title":"J. Mater. Process. Technol."},{"issue":"2","key":"41272_CR27","first-page":"18","volume":"28","author":"G Nicoletto","year":"2010","unstructured":"Nicoletto, G. & L. Ceschini. Influence of solidification microstructure and porosity on the fatigue strength of Al\u2013Si\u2013Mgcasting alloys. J. Meta. Sci. & Technol. 28(2), 18\u201324 (2010).","journal-title":"J. Meta.Sci. & Technol."},{"key":"41272_CR28","doi-asserted-by":"crossref","unstructured":"Wang, D., et al. Solidification microstructures and softening behavior of laser welded 6082-A356 aluminum alloy dissimilar butt joints. Materials today communications 38, 10841 (2024).","DOI":"10.1016\/j.mtcomm.2024.108411"},{"key":"41272_CR29","doi-asserted-by":"crossref","unstructured":"Wang, X., et al. Achieving balanced mechanical-corrosion properties in laser-welded Al-Mg-Si-Cu alloy welds by Ti content optimization. Materials & Design. 260, 115244 (2025).","DOI":"10.1016\/j.matdes.2025.115244"},{"key":"41272_CR30","doi-asserted-by":"crossref","unstructured":"Gupta S.P. Intermetallic compound formation in Al\u2013Fe\u2013Si ternary system: Part I. Mater. Char. 49(4), 269\u2013291 (2002).","DOI":"10.1016\/S1044-5803(03)00006-8"},{"key":"41272_CR31","doi-asserted-by":"crossref","unstructured":"Xu, C.& Li, G et al. Precipitation behaviour and Phase stability in AL-Cu-Mg-Li-Sc alloys during aging. J. Alloys Compd. 1010, 177927 (2025).","DOI":"10.1016\/j.jallcom.2024.177927"},{"key":"41272_CR32","first-page":"121","volume":"21","author":"C Chen","year":"2023","unstructured":"Chen, C., Zhang, H. & Huijing, Z. Influence of heat input on the appearance, microstructure and microhardness of pulsed gasmetal arc welded Al alloy weldment. J. Mater. Rese. Technol. 21, 121\u2013130 (2022).","journal-title":"J. Mater. Process. Technol."},{"key":"41272_CR33","doi-asserted-by":"publisher","first-page":"2491","DOI":"10.1007\/s11668-025-02292-7","volume":"125","author":"R Patil","year":"2025","unstructured":"Patil, R. & L\u00f6fstrand, M. Detection and classification of engine exhaust weld joint defects using RNN and SVM on 316L-SS410 and SS310- SS410. J. Fail. Anal. Prev. 125, 2491\u20132511 (2025).","journal-title":"J. Fail. Anal. Prev."},{"key":"41272_CR34","doi-asserted-by":"publisher","first-page":"913","DOI":"10.1007\/s00170-022-10719-w","volume":"125","author":"RV Patil","year":"2023","unstructured":"Patil, R. V. & Reddy, Y. P. Multiform weld joint flaw detection and classification by sagacious artificial neural network technique. Int. J. Adv. Manuf. Technol. 125, 913\u2013943 (2023).","journal-title":"Int. J. Adv. Manuf. Technol."},{"key":"41272_CR35","doi-asserted-by":"publisher","DOI":"10.1007\/s10921-021-00801-w","volume":"40","author":"RV Patil","year":"2021","unstructured":"Patil, R. V. & Reddy, Y. P. An autonomous technique for multi class weld imperfections detection and classification by support vector machine. J. Nondestruct. Eval. 40, 76 (2021).","journal-title":"J. Nondestruct. Eval."},{"key":"41272_CR36","doi-asserted-by":"publisher","first-page":"367","DOI":"10.1007\/978-981-15-9829-6_28","volume":"206","author":"RV Patil","year":"2021","unstructured":"Patil, R. V. & Reddy, Y. P. Weld imperfection classification using texture features and LBP. Smart Innov. Syst. Technol. 206, 367\u2013378 (2021).","journal-title":"Smart Innov. Syst. Technol."},{"key":"41272_CR37","doi-asserted-by":"publisher","first-page":"429","DOI":"10.1007\/978-981-15-9829-6_33","volume":"206","author":"RV Patil","year":"2021","unstructured":"Patil, R. V. & Reddy, Y. P. Multi-class weld defect detection using SVM and ANN. Smart Innov. Syst. Technol. 206, 429\u2013438 (2021).","journal-title":"Smart Innov. Syst. Technol."},{"key":"41272_CR38","doi-asserted-by":"crossref","unstructured":"Patil, R. V. & Thote, A. M. Smart techniques of microscopic image analysis and real-time temperature measurement for quality welds. In Soft Computing in Materials Development and Sustainability, 49\u201372 (CRC Press, 2022).","DOI":"10.1201\/9781003154518-4"},{"key":"41272_CR39","doi-asserted-by":"crossref","unstructured":"Patil, R. V. & Reddy, Y. P. Correlation assessment of weld bead geometry and temperature circulation by online measurement in Nd:YAG laser welding. In Advances in Engineering Materials, Lecture Notes in Mechanical Engineering, 21\u201329 (2021).","DOI":"10.1007\/978-981-33-6029-7_3"},{"key":"41272_CR40","doi-asserted-by":"publisher","first-page":"132","DOI":"10.1007\/s40516-026-00329-9","volume":"13","author":"R Patil","year":"2026","unstructured":"Patil, R. & L\u00f6fstrand, M. High power diode laser beam welding of SS304 stainless steel: Influence of process parameters on weld quality and mechanical performance. Lasers Manuf. Mater. Process. 13, 132\u2013154 (2026).","journal-title":"Lasers Manuf. Mater. Process."},{"key":"41272_CR41","doi-asserted-by":"crossref","unstructured":"Patil, R. & L\u00f6fstrand, M. Integrated experimental FE analysis of temperature distribution, molten metal flow, and residual stress in GTAW dissimilar metal welds for engine exhaust system. Int. J. Adv. Manuf. Technol. 142, 6057\u20136079 (2026).","DOI":"10.1007\/s00170-025-17333-6"},{"key":"41272_CR42","doi-asserted-by":"publisher","DOI":"10.3390\/met11111680","volume":"11","author":"I Bunaziv","year":"2021","unstructured":"Bunaziv, I. et al. A review on laser-assisted joining of aluminium alloys to other metals. Metals 11, 1680 (2021).","journal-title":"Metals"}],"container-title":["Scientific Reports"],"original-title":[],"language":"en","link":[{"URL":"https:\/\/www.nature.com\/articles\/s41598-026-41272-1","content-type":"text\/html","content-version":"vor","intended-application":"text-mining"},{"URL":"https:\/\/www.nature.com\/articles\/s41598-026-41272-1.pdf","content-type":"application\/pdf","content-version":"vor","intended-application":"text-mining"},{"URL":"https:\/\/www.nature.com\/articles\/s41598-026-41272-1.pdf","content-type":"application\/pdf","content-version":"vor","intended-application":"similarity-checking"}],"deposited":{"date-parts":[[2026,7,14]],"date-time":"2026-07-14T15:01:00Z","timestamp":1784041260000},"score":1,"resource":{"primary":{"URL":"https:\/\/www.nature.com\/articles\/s41598-026-41272-1"}},"subtitle":[],"short-title":[],"issued":{"date-parts":[[2026,2,26]]},"references-count":42,"journal-issue":{"issue":"1","published-online":{"date-parts":[[2026,12]]}},"alternative-id":["41272"],"URL":"https:\/\/doi.org\/10.1038\/s41598-026-41272-1","relation":{},"ISSN":["2045-2322"],"issn-type":[{"value":"2045-2322","type":"electronic"}],"subject":[],"published":{"date-parts":[[2026,2,26]]},"assertion":[{"value":"21 January 2026","order":1,"name":"received","label":"Received","group":{"name":"ArticleHistory","label":"Article History"}},{"value":"19 February 2026","order":2,"name":"accepted","label":"Accepted","group":{"name":"ArticleHistory","label":"Article History"}},{"value":"26 February 2026","order":3,"name":"first_online","label":"First Online","group":{"name":"ArticleHistory","label":"Article History"}},{"value":"18 June 2026","order":6,"name":"change_date","label":"Change Date","group":{"name":"ArticleHistory","label":"Article History"}},{"value":"Update","order":7,"name":"change_type","label":"Change Type","group":{"name":"ArticleHistory","label":"Article History"}},{"value":"The original online version of this Article was revised: In the original version of this Article the References 21, 23, 24, 25, 27, 28, 29, 30, 31, 32, 40, and 41 were incorrect as there were DOI\/Metadata changes. The original Article has been corrected.","order":8,"name":"change_details","label":"Change Details","group":{"name":"ArticleHistory","label":"Article History"}},{"value":"Not applicable.","order":1,"name":"Ethics","group":{"name":"EthicsHeading","label":"Competing interests"}}],"article-number":"7738"}}