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<p>Ti-6Al-4V alloy is extensively used in aerospace and automotive applications due to its high strength-to-weight ratio, excellent corrosion resistance, and superior mechanical properties. In this study, the influence of flux coating and post-weld heat treatment (PWHT) on the characteristics of CO<sub>2</sub> laser-welded Ti-6Al-4V plates was investigated. Bead-on-plate welding experiments were performed under varying laser power and welding speed using uncoated, Al<sub>2</sub>O<sub>3</sub>-coated, and ZnO-coated surfaces. The welded specimens were characterized through macrostructural examination, scanning electron microscopy (SEM), microhardness measurements, and residual stress analysis. The results show that flux coatings enhance weld penetration and promote microstructural refinement in the fusion zone. ZnO-coated specimens exhibited a maximum weld zone height of 5.11&#xa0;mm compared to 4.81&#xa0;mm for the uncoated condition, while fusion zone hardness increased up to ~ 540&#xa0;HV. Residual stress measurements confirmed the development of beneficial compressive stresses reaching ~  − 51&#xa0;MPa in ZnO-coated welds. Post-weld heat treatment further improves hardness distribution and induces beneficial compressive residual stresses. In addition, a support vector regression (SVR) model was developed to predict weld responses such as weld zone height, hardness, and residual stress using welding parameters as inputs. The predicted results exhibited good agreement with experimental observations, highlighting the potential of machine learning for predictive analysis and process optimization in laser welding of Ti-6Al-4V alloys.</p>

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Effect of Oxide Flux Coatings and Post-weld Heat Treatment on CO2 Laser-Welded Ti-6Al-4V Alloy

  • 期刊论文

  • 发表日期：

    2026年6月26日

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  • G. Muthu Kumaran,
  • R. Rengarajan,
  • P. Marimuthu,
  • P. Dinesh Babu

摘要

Ti-6Al-4V alloy is extensively used in aerospace and automotive applications due to its high strength-to-weight ratio, excellent corrosion resistance, and superior mechanical properties. In this study, the influence of flux coating and post-weld heat treatment (PWHT) on the characteristics of CO2 laser-welded Ti-6Al-4V plates was investigated. Bead-on-plate welding experiments were performed under varying laser power and welding speed using uncoated, Al2O3-coated, and ZnO-coated surfaces. The welded specimens were characterized through macrostructural examination, scanning electron microscopy (SEM), microhardness measurements, and residual stress analysis. The results show that flux coatings enhance weld penetration and promote microstructural refinement in the fusion zone. ZnO-coated specimens exhibited a maximum weld zone height of 5.11 mm compared to 4.81 mm for the uncoated condition, while fusion zone hardness increased up to ~ 540 HV. Residual stress measurements confirmed the development of beneficial compressive stresses reaching ~  − 51 MPa in ZnO-coated welds. Post-weld heat treatment further improves hardness distribution and induces beneficial compressive residual stresses. In addition, a support vector regression (SVR) model was developed to predict weld responses such as weld zone height, hardness, and residual stress using welding parameters as inputs. The predicted results exhibited good agreement with experimental observations, highlighting the potential of machine learning for predictive analysis and process optimization in laser welding of Ti-6Al-4V alloys.