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<p>This study investigates T-lap laser welding of selective laser melting-fabricated 3D-GH3536 and rolled solution-treated R-GH3128 dissimilar nickel-based superalloys. The weld microstructure primarily consisted of columnar crystals symmetrically distributed on both sides of the centerline and equiaxed grains near the center. Under optimal parameters (laser power 2800 W, defocus distance + 10&#xa0;mm, welding speed 2.7&#xa0;m/min), the weld zone exhibited a microhardness of 243 HV and tensile shear strength of 828&#xa0;MPa, achieving 98.7% joint efficiency relative to R-GH3128, representing a 2.7-fold improvement compared to previous GH-series dissimilar welding studies. Significantly, increasing defocus distance effectively mitigated continuous porosity defects by reducing laser energy density. The optimized parameters demonstrated excellent adaptability to assembly gaps of 0-0.3&#xa0;mm, consistently producing well-formed welds with minimal porosity. Despite extensive research on laser welding of nickel-based superalloys, critical knowledge gaps remain regarding porosity control and assembly gap tolerance when joining dissimilar additively manufactured and conventionally processed materials in T-lap configurations. This work systematically addresses these challenges, providing practical guidelines for aerospace manufacturing applications.</p>

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Microstructural and Mechanical Properties of Laser-Welded 3D-GH3536/R-GH3128 T-Joints

  • 期刊论文

  • 发表日期：

    2026年2月16日

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  • Yunhao Gong,
  • Pengfei Guo,
  • Minxuan Yang,
  • Huanrong Wang,
  • Jianfeng Gong,
  • Shuai Chang,
  • Liqun Li

摘要

This study investigates T-lap laser welding of selective laser melting-fabricated 3D-GH3536 and rolled solution-treated R-GH3128 dissimilar nickel-based superalloys. The weld microstructure primarily consisted of columnar crystals symmetrically distributed on both sides of the centerline and equiaxed grains near the center. Under optimal parameters (laser power 2800 W, defocus distance + 10 mm, welding speed 2.7 m/min), the weld zone exhibited a microhardness of 243 HV and tensile shear strength of 828 MPa, achieving 98.7% joint efficiency relative to R-GH3128, representing a 2.7-fold improvement compared to previous GH-series dissimilar welding studies. Significantly, increasing defocus distance effectively mitigated continuous porosity defects by reducing laser energy density. The optimized parameters demonstrated excellent adaptability to assembly gaps of 0-0.3 mm, consistently producing well-formed welds with minimal porosity. Despite extensive research on laser welding of nickel-based superalloys, critical knowledge gaps remain regarding porosity control and assembly gap tolerance when joining dissimilar additively manufactured and conventionally processed materials in T-lap configurations. This work systematically addresses these challenges, providing practical guidelines for aerospace manufacturing applications.