Automation & Control

With the increasing demand for lightweight and high-strength-toughness materials in aerospace, military, and high-end equipment manufacturing, titanium alloy laser welding technology (multi-layer overlay welding) has been widely applied. However, titanium alloys are highly prone to microcracks during multi-layer laser welding, especially in the heat-affected zone (HAZ) and the interface between weld layers. These microcracks are often invisible or difficult to detect in time using traditional methods, severely impacting the fatigue strength and service life of welded joints.Industry engineers frequently report on forums like AWS, WeldingWeb, and Reddit r/welding: "Despite process adjustments, it's still difficult to completely avoid microcrack formation in multi-layer laser welding of titanium alloys, and crack locations are unpredictable," and "Existing non-destructive testing methods are limited, repair costs are high, and fully automated online monitoring cannot be achieved." In recent Google Scholar and ScienceDirect research on titanium alloy laser welding over the past two years, microcrack suppression mechanisms and real-time internal weld monitoring remain major challenges. Multiple recent patents attempt to mitigate thermal stress and optimize waveform parameters, but due to complex microstructural transformations, none have formed mature industrial solutions.Quality fluctuations caused by microcracks have become a core bottleneck restricting the large-scale, automated production of titanium alloy multi-layer laser overlay welding, presenting high technical barriers and immense innovation potential.