Multiscale characterization of NiTi shape memory alloy to Ti6Al4V dissimilar laser welded joints: Reasons for inherent brittleness

• Defect-free NiTi shape memory alloy to Ti6Al4V laser welded joints obtained. • Multiscale characterization across the welded joint reveal the role of brittle Ti 2 Ni. • The fraction of brittle Ti 2 Ni varies across the welded joint due to material dilution. • Excellent agreement between nanohardness and fraction of Ti 2 Ni is obtained. Dissimilar joining of advanced engineering alloys is of major importance for several applications to take advantage of the properties of each one of the base materials. Due to the formation of Ti 2 Ni and to the thermal expansion coefficient mismatch, dissimilar laser welding between Ti6Al4V and NiTi is particularly challenging. Nevertheless, a joint without pores or cracks was obtained using a Nd:YAG laser system with a wavelength of 1064 nm and a spot size of 0.45 mm. Full-penetration occurred and the weld pool is asymmetric with a key-hole shape. Typical dendritic structure is observed throughout the welded zone, although without apparent orientation on the middle. Close to the Ti6Al4V side a zone with a different morphology is observed along the entire thickness with high hardness corresponding to NiTi 2 . Multiscale microstructure and mechanical characterization encompassing electron microscopy, synchrotron X-ray diffraction, electron probe microanalysis and instrumented nanoindentation were used to reveal the microstructure/properties relationships correlating the extremely high hardness and brittleness of the welded joint to its microstructural constituents