THERMOMECHANICAL BEHAVIOR AND MICROSTRUCTURE OF LASER-HYBRID AND ELECTRON-BEAM WELDED JOINTS OF TITANIUM ALLOYS
Abstract
This study presents a comprehensive thermomechanical analysis of residual stress formation and structural evolution during laser-hybrid welding of Ti-6Al-4V titanium alloy. The main objective is to evaluate the influence of process parameters on temperature distribution, weld morphology, and residual stress development. Finite element modeling (FEM) was employed to simulate heat transfer, thermal gradients, and plastic deformation, and the results were validated using experimental data from laser-GTA and electron beam welding studies. Microstructural analysis of the weld metal (WM), heat-affected zone (HAZ), and base metal (BM) revealed a gradient of α and β phases, influenced by local thermal cycles. Results demonstrate that laser-hybrid welding produces a narrower fusion zone and a reduced HAZ compared to conventional TIG and EBW methods, enhancing structural uniformity. Longitudinal residual stresses were highest along the weld centerline but were significantly reduced after ultrasonic impact treatment (UIT), confirming its effectiveness in stress relaxation. Comparative analysis indicates that LHW provides superior control over thermal gradients and microstructure, ensuring improved mechanical performance and dimensional stability of welded components. The study establishes correlations between energy input, weld geometry, microstructural features, and residual stress distribution, which are critical for optimizing welding parameters. The findings contribute to designing advanced titanium structures with enhanced reliability for aerospace and transport engineering applications. Overall, the results highlight that the combination of laser-hybrid welding and UIT represents a promising approach for manufacturing high-performance titanium alloy components.
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Copyright (c) 2025 Svitlana Kyrylakha, Світлана Кирилаха (Автор)
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