Unravelling the mechanism of columnar-to-equiaxed transition and grain refinement in ultrasonic vibration assisted laser welding of Ti6Al4V titanium alloy.

In this study, the microstructural evolution and mechanical properties of Ti6Al4V titanium alloy welded joints subjected to ultrasonic assisted laser welding were scrutinized, while numerical simulations were employed to explicate the grain refinement mechanism. The simulations indicate that the ultrasonic vibration significantly improves the overall fluidity and temperature of the molten pool. Under the identical condition of laser power and welding speed (1500 W, 1.3 m/min), the presence of 0.2A ultrasonic current yields a more uniform refinement of columnar grains, along with a denser arrangement of acicular martensite. The refinement mechanism can be attributed to the small temperature gradient, cavitation effects, and stress induced by ultrasonic vibration. Notably, the welded joint attains a peak tensile strength of 945.2 MPa under the aforementioned 0.2A condition, distinctly demonstrating the characteristics of ductile fracture. This research further reveals the underlying mechanism of grain refinement in Ti6Al4V alloy laser-welded joints induced by ultrasonic vibration, providing valuable references for optimizing process parameters and improving the quality of such welded joints.