Al matrix composites (AMCs) are preferred engineering materials for aerospace and automotive industries owing to their high specific strength, superior wear resistance and low thermal expansion. It is a challenge to achieve high-quality fusion welded joints of AMCs because of the occurrence of defects such as pores, particles segregation and acicular phases. In this study, the effects of laser welding parameters including laser power, welding speed and laser incident angle on the formation of porosity and acicular phase were investigated in SiCp/6092 aluminum matrix composite welded joints using orthogonal experimental method. Range analysis of the orthogonal test results showed that the laser power and the welding speed had the greatest influence on the porosity and acicular phase size during the laser welding of aluminum matrix composites. At a heat input of 60 J/mm, the porosity in the weld was only 1.6% while that at 190 J/mm was 15.2%. Higher heat input produced a much larger size of brittle Al4C3 phases. The size of the acicular phase Al4C3 at the top and bottom of the weld was larger than that in the middle. Active Ti was added to the weld zone to mitigate the adverse effect of Al4C3 brittle phase and porosity on mechanical properties. The ultimate tensile strength increased from 115 MPa in direct laser welding to 148 MPa for the laser welding process employing the Ti interlayer. This work will provide referenceable data for designing high-quality AMC welded joints for aerospace and automotive industries.
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