A 10 mm narrow gap TC4 titanium alloy welded joint by laser welding with filler wire was obtained by different welding heat inputs. The microstructures of the welded joint were analyzed by OM, SEM, XRD and EBSD. The mechanical properties of the welded joint were analyzed by microhardness test and tensile test. The results show that with the increase of laser welding heat input, the average grain size and width of the equiaxed crystal zone in the center of the weld increases, the grain angle in the columnar crystal zone gradually tends to be perpendicular to the center of the weld, and the width of the heat affected zone (HAZ) increases without obvious grain coarsening. The HAZ of the welded joint is softened, and its microhardness value is lower than that of the weld and the base metal. The tensile strength of the welded joint is slightly higher than those of the base metal, but the elongation after fracture is less than that of the base metal, and it decreases with the increase of laser welding heat input.

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In order to investigate the effect of welding sequence on stress distribution and deformation of Mg alloy fillet welds, DE-GMAW modified Gaussian heat source model established by MSC. Marc software was applied to the numerical simulation analysis of welding temperature field and stress field and proved by measurement of residual stress by blind hole method. The results indicated that the deformation and residual stress were lowest according to the sequence of welding fillet welds from the head of cylinder to the end on one side first and then welding in the opposite on the other side. The trend of residual stress measurement results was consistent with numerical simulation analysis results with 10% error, which provided theoretical support for stress distribution and deformation control of Mg alloy fillet welds.