Microstructure and Mechanical Properties of Wire Laser Additive Manufactured Deposits and Their Tungsten Inert Gas Welds

Ti-6Al-4V (Ti64) alloy is widely utilized in the aerospace industry due to its high strength, fatigue resistance, corrosion resistance, and cryogenic properties. However, its high raw material costs and machining difficulties necessitate the development of efficient manufacturing processes. This study evaluates the mechanical reliability and microstructure of Ti64 components fabricated using wire laser additive manufacturing (WLAM) and subsequently joined via tungsten inert gas (TIG) welding. The WLAM process produces refined microstructures with superior mechanical properties by minimizing defects; however, insufficient process optimization may result in a lack of fusion (LOF) and porosity. Microstructural analysis revealed that the WLAM deposits exhibited a fine basket-weave alpha structure with an average alpha-lath width of 1.27 +/- 0.69 mu m, while the TIG-welded region exhibited a coarsened alpha-lath, reaching 3.02 +/- 2.06 mu m, which led to a reduction in ductility. Tensile testing demonstrated that the WLAM deposits exhibited superior mechanical properties, with a yield strength of 910 MPa, ultimate tensile strength of 1015 MPa, and elongation of 12.8%, outperforming conventional wrought Ti64 alloys. Conversely, the TIG-welded joints exhibited reduced mechanical properties, with a yield strength of 812 MPa, ultimate tensile strength of 917 MPa, and elongation of 7.5%, primarily attributed to microstructural coarsening in the weld region. The findings of this study confirm that WLAM enhances the mechanical properties of Ti64, whereas TIG welding may introduce structural weaknesses. This research provides insight into the microstructural evolution and mechanical behavior of WLAM-fabricated Ti64 components, with valuable implications for their application in aerospace structures.