The influence of pulsed laser beam welding (LBW) parameters on the weld geometry and imperfections of a new nickel-based superalloy called G27 was studied by a statistical design of experiment, and the microstructures of the weld fusion zone (FZ) of the pulsed laser beam-welded G27 were characterized. No evidence of cracks is found in the FZ and heat-affected zone (HAZ). Other weld imperfections, such as undercut and underfill, were also hardly observed.

The pulse factor significantly influenced all the responses, i.e., minimum weld width (Wm), root excess weld metal, and average pore diameter, whereas welding travel speed significantly influenced Wm and root excess weld metal. Power and interaction between pulse frequency*pulse factor were statistically significant in influencing the root excess weld metal and average pore diameter, respectively. The pulse frequency and interactions between power*travel speed, power*pulse factor, power*pulse frequency, travel speed*pulse factor, and travel speed*pulse frequency did not significantly influence any response.

Microsegregation pattern that occurs during weld solidification leads to the formation of Nb-rich MC carbides and Nb-rich Laves phase as the major secondary phase constituents in the FZ of as-welded G27. The presence of brittle Laves phase requires careful consideration when developing suitable post-weld heat treatment of G27.