Disk-laser welding of Hastelloy X cover on René 80 turbine stator blade

Nickel-base alloys, such as Hastelloy X and Rene 80, are among the most common ones for aerospace applications, due to their mechanical strength at high temperatures and oxidation resistance properties, although processing for missile and space vehicle applications requires extensive fusion and resistance welding for fastening. Laser welding using a Yb:YAG disk laser in continuous mode emission is investigated in this paper for overlap joining of Hastelloy X plates on Rene 80 samples resulting from waste turbine blades. An explorative study is carried out in order to find an appropriate processing window as well as discussing bead features and common issues. Special fixtures for clamping have been specifically developed and tested. A 3-factors study with power, welding speed and focus position as governing parameters has been arranged; 2 levels have been chosen for each factor. Geometric features, defects and indications are discussed referring to the parameters main effects.