Ensuring consistent processing quality is challenging in laser processes due to varying material properties and surface conditions. Although some approaches have shown promise in solving this problem via automation, they often rely on predetermined targets or are limited to simulated environments. To address these shortcomings, we propose a novel real-time reinforcement learning approach for laser process control, implemented on a Field Programmable Gate Array to achieve real-time execution. Our experimental results from laser welding tests on stainless steel samples with a range of surface roughnesses validated the method's ability to adapt autonomously, without relying on reward engineering or prior setup information. Specifically, the algorithm learned the correct power profile for each unique surface characteristic, demonstrating significant improvements over hand-engineered optimal constant power strategies -- up to 23% better performance on rougher surfaces and 7% on mixed surfaces. This approach represents a significant advancement in automating and optimizing laser processes, with potential applications across multiple industries.

To advance quality assurance in the welding process, this study presents a robust deep learning model that enables the prediction of two critical welds Key Performance Characteristics (KPCs): welding depth and average pore volume. In the proposed approach, a comprehensive range of laser welding Key Input Characteristics (KICs) is utilized, including welding beam geometries, welding feed rates, path repetitions for weld beam geometries, and bright light weld ratios for all paths, all of which were obtained from hairpin welding experiments. Two deep learning networks are employed with multiple hidden dense layers and linear activation functions to showcase the capabilities of deep neural networks in capturing the intricate nonlinear connections inherent within welding KPCs and KICs. Applying deep learning networks to the small numerical experimental hairpin welding dataset has shown promising results, achieving Mean Absolute Error (MAE) values as low as 0.1079 for predicting welding depth and 0.0641 for average pore volume. Additionally, the validity verification demonstrates the reliability of the proposed method. This, in turn, promises significant advantages in controlling welding outcomes, moving beyond the current trend of relying merely on monitoring for defect classification.