Effect of Nd:YAG laser beam welding on weld morphology and mechanical properties of Ti–6Al–4V butt joints and T-joints

• Nd:YAG laser beam welding of Ti–6Al–4V using filler wire was successfully achieved.
• Butt joints and T-joints showed low porosity levels and appropriate seam geometries.
• Base material level of strength achieved for butt joints and T-joints.
• Performance in pull-out test is sensitive to weld shape and weld morphology.

A Nd:YAG single-sided laser beam welding process study for Ti–6Al–4V butt joints and T-joints was performed to investigate joining techniques with regard to the process-weld morphology relationship. An alloy compatible filler wire was used to avoid underfills and undercuts. The quality of the butt joints and T-joints was characterized in terms of weld morphology, microstructure and mechanical properties. Joints with regular shapes, without visible cracks, pores, and geometrical defects were achieved. Tensile tests revealed high joint integrity in terms of strength and ductility for both the butt joint and T-joint geometries. Both the butt joints and T-joints showed base material levels of strength. The mechanical performance of T-joints was also investigated using pull-out tests. The performance of the T-joints in such tests was sensitive to the shape and morphology of the welds. Fracture always occurred in the weld without any plastic deformation in the base material outside the weld.