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Laser welding is a feasible process for joining the additive manufactured (AMed) parts to meet the manufacturing demand of specific large-scale components. Microstructure and property evolution as well as weldability of the laser welding of wire arc additive manufactured (WAAMed) Al-Cu alloy are investigated. Results indicate that the WAAMed Al-Cu alloy has excellent laser weldability and the joint is nearly free of defect. The width of the heat-affected-zone (HAZ) and equiaxed crystal zone (EQZ) as well as the grain size of the fusion zone (FZ) will increase with higher laser power and heat input. The joint with laser power of 3500 W has the highest tensile strength and elongation, reaching 203.48 MPa and 4.13%. The result from electron backscatter diffraction (EBSD) test indicates that the texture intensity will affect tensile properties. The tensile strength and elongation of the laser welded WAAM sample perpendicular to the deposition direction are higher than that parallel to the deposition direction. The microhardness value of HAZ is higher than that of FZ and BM due to 163 HV. The feasibility of laser welding of WAAMed samples is validated, and process parameters are found for hybrid manufacturing of large-scale components. [ABSTRACT FROM AUTHOR]

The bottom-locking joint is widely used in the aerospace manufacturing field as an imperative connection structure. The laser welding experiment for the Ti-6Al-4V titanium alloy bottom-locking joint is carried out in the present paper. Meanwhile, porosity in the weld seam including the process porosity and metallurgical porosity is investigated. Furthermore, it is novel that the distribution, element characteristics, and formation mechanism of process porosities and metallurgical porosities in the bottom-locking joint are comprehensively analysed based on the porosity morphology, microstructure, and element analysis of the resultant bottom-locking joints. The process porosity, which mainly appeared in the weld seam centre, is formed by the combined effect of two mechanisms which closely related to the dynamic behaviour of the molten pool and the stability of the keyhole. Besides, a large number of micropores with a diameter of 2–5 µm are observed on the surface of the process porosity, whose formation is related to the evaporation of elements. Moreover, the tensile stress generated during the solidification and shrinkage of the molten metal is the main factor leading to microcracks in the micropores. The nucleation characteristics of bubbles cause metallurgical porosities to be mainly distributed at the bottom of the weld seam. [ABSTRACT FROM AUTHOR]