The development and application of laser welding transition layer technology is pivotal for manufacturing high-performance diamond saw blades. Despite its importance, there is a need for more precise modeling to optimize welding parameters and enhance blade performance. This study employs SYSWELD software to simulate the laser welding process, demonstrating high accuracy in predicting the molten pool shape. A cross-scale multi-field coupling model was established using the finite element method, incorporating temperature field, phase transformation, grain morphology, stress field, and fatigue performance. A comprehensive life cycle assessment identified optimal welding parameters. The results indicate that a laser welding speed of 26 mm/s and a power of 1700 W minimize weld stress, reduce the digital volume correlation (DVC) value, and enhance fatigue resistance. Additionally, welding tests confirmed that using 1700 W produced the highest tooth strength of 1200 MPa, validating the simulation results. This study addresses existing gaps in modeling accuracy and parameter optimization, offering a robust framework for improving the performance and reliability of laser-welded diamond saw blades.
