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Synergistic effect of alternating magnetic field and V/CuCrZr/Monel-400 composite interlayer on microstructure and mechanical performance of TC4/304-SS laser welded joints
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DOI：10.1016/j.optlastec.2026.116094.png)
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Abstract
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Laser welding of TC4 and 304-SS is fundamentally constrained by brittle Ti-Fe intermetallic compounds (IMCs) formation and poor metallurgical compatibility. In this study, a magnetohydrodynamic (MHD) assisted laser welding approach is developed by combining an alternating magnetic field (AMF) with a V/CuCrZr/Monel-400 composite interlayer to regulate molten pool dynamics and interfacial reactions. The applied AMF induces strong convection within the molten pool. Consequently, heat and mass transfer are enhanced, promoting interlayer dissolution and elemental redistribution. As a result, the fraction of unmelted CuCrZr decreases by 63.5%. This promotes the formation of a more homogeneous and compositionally graded fusion zone. The joint microstructure is dominated by continuous β-(Ti, V) and γ-(Fe, Ni) solid-solution phases. These phases reducing the tendency for the formation of detrimental Ti-Fe intermetallic compounds (IMCs). This improved microstructural uniformity increases the minimum hardness from 136.4 HV to 165.5 HV and enhances the ultimate tensile strength from 457.7 MPa to 484.6 MPa. In addition, the fracture mode shifts from Cu-rich interlayer failure to a stronger interface-controlled mechanism. The results demonstrate that the combined effect of AMF-induced convection and composite interlayer design provides an effective strategy for microstructure control and performance enhancement in dissimilar TC4/304-SS laser welding.
Keywords:
Laser welding
Titanium alloy
Stainless steel
Alternating magnetic field
Magnetohydrodynamic
Microstructure
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