The effect of welding speed on the microstructure and mechanical properties of laser-CMT hybrid welded joints of 6 mm thick low carbon steel (Q235) was investigated in this research. The weld zone (WZ) primarily comprised proeutectoid ferrite, side-plate ferrite, and acicular ferrite. For heat-affected zone (HAZ), the microstructure consisted of ferrite, pearlite, and widmanstatten. As the welding speed increased from 1.2 m/min to 2.1 m/min, the following trends were observed: weld appearance initially stabilized but deteriorated at higher speeds; bainite microstructure was found in WZ; the average grain size decreased from 2.47 to 1.35 mu m; the proportion of high angle grain boundaries was increased from 46.5% to 69.4%; the average value of KAM increased from 0.48 degrees to 1.17 degrees. This phenomenon is due to the increase in cooling rate and the reduction in heat input. Besides, the tensile strength of welded joints showed a trend of initial increase and subsequent decrease, while the microhardness of the WZ showed a gradual increase. The maximum average hardness was achieved at a welding speed of 2.1 m/min; however, a significant deterioration in toughness was observed at this speed. Within the range of welding speeds tested, the most favorable welding speed was 1.5 m/min, with the tensile strength of welded joint reaching 717 MPa +/- 11 MPa, elongation reaching 12.5% +/- 0.4%and average microhardness of the WZ reaching 197 HV, which was much higher than the base metal.

To investigate the microstructure and mechanical anisotropy of as-deposited GH3536 alloy specimens fabricated by Selective Laser Melting (SLM), this study combines experiments and numerical simulations. By optimizing the laser power, scanning speed, and scanning strategy, the optimal process parameters were determined: a volumetric energy density of 83.3 J/mm(3) and a 67 degrees spiral scanning strategy. Transient heat conduction simulation using Abaqus showed that the extremely high temperature gradients and cooling rates during the SLM process induce fine cellular crystals and dislocation networks at the molten pool boundaries; columnar crystals grow along the Building Direction (BD), forming a <110> texture in the Width Direction (WD) and a strong <100> texture in the Thickness Direction (TD). The synergistic strengthening of dislocations and texture yields the highest strength along the thickness direction (TD), which possesses a higher molten pool boundary density. The tensile strength (TS) and yield strength (YS) reach 810 MPa and 572 MPa, and the tensile strength is 36% and 7.1% higher than those along the building direction (BD) and width direction (WD), respectively. This study clarifies the microstructural evolution and mechanical anisotropy of SLM-processed GH3536 alloy, providing a foundation for the subsequent optimization of forming processes and performance regulation.

The oscillation frequency of the laser plays a significant role in determining the formation quality, grain structure, and mechanical properties of laser-CMT hybrid welded joints in high-magnesium aluminum alloys. Oscillating laser technology is employed to mitigate welding defects, optimize the weld microstructure, and enhance the mechanical performance of these alloys. In this study, laser oscillation frequencies of 0, 100, 150, 200, and 250 Hz were investigated. The microstructure of the welded joints was analyzed using Transmission Electron Microscopy (TEM) and Electron Backscatter Diffraction (EBSD). The precipitated phases included the α-Al matrix phase and secondary phases, such as Mg2Si and MgZn2. At 0 Hz, the weld formation was suboptimal, characterized by severe defects and coarse grain structures. Increasing the oscillation frequency initially resulted in grain refinement, but further increases led to grain coarsening. The smallest grain size and the highest fraction of equiaxed grains were observed at 200 Hz. At this frequency, the volume fraction of Σ3 grain boundaries was also at its highest. The oscillating laser effectively suppressed columnar grain growth and promoted grain refinement in this region. The mechanical properties of the welded joint exhibited a trend of first increasing and then decreasing with rising oscillation frequencies. At 0 Hz, the tensile strength of the welded joint was only 215.84 MPa, while at 200 Hz, the mechanical properties were optimized, reaching 324.85 MPa. Swing laser welding optimizes weld microstructure and enhances the mechanical properties of welded joints.

The corrosion property of dissimilar steel welded joints used in ocean industry was seriously compromised by heterogeneous microstructures and detrimental phase precipitation. In this study, the poor microstructure of dissimilar welded joints was homogenized and the corrosion behavior was enhanced via optimized high temperature solution treatment. The results demonstrated that the initial as-welded coarse and segregated microstructure was effectively homogenized and transformed into a homogeneous austenite matrix (83.7%) with finely distributed skeletal ferrite (11.8%) and minimal sigma-phase (4.4%) after 1050 degrees C post-weld heat treatment(PWHT) for 2 h. In contrast, microstructural heterogeneity and elemental segregation were aggravated by lower PWHT temperatures. Electrochemical characterization revealed that the 1050 degrees C/2 h PWHT sample exhibited optimal corrosion resistance, evidenced by the highest charge transfer resistance (9.18 & times; 106 Omega) and the lowest passive current density (4.52 & times; 10-6 A/cm2), representing a 16.3% increase and an 21.3% reduction compared to the aswelded condition, respectively. Moreover, a better re-passivation capability, characterized by the most noble protection potential (Ecorr2 approximate to 0.5 V) was demonstrated by this condition in cyclic voltammetry(CV) tests. The enhanced corrosion performance was attributed to the homogenized microstructure and the resultant continuous and stable Cr-rich passive film (primarily FeCr2O4 and Cr2O3), effectively suppressing pit initiation and accelerating re-passivation. This work provided valuable insights for optimizing heterogeneous microstructures to enhance the durability of dissimilar steel welded joints in corrosive environments.

The second phase strengthening is the key strengthening mechanism influencing the mechanical properties of Al-Zn-Mg-Cu alloy fusion welded joints. However, Al2CuMg phases give rise to intergranular failure by micro-void nucleation due to the plastic incompatibility between soft grains (low precipitate density) and hard phases (segregation at grain boundaries). To this end, we investigated the effects of in-situ generation of Al3Zr within welded joints on microstructure and mechanical properties, focusing on the tuning mechanism of the dual-scale second phases. The results indicated that Al3Zr, as a heterogenous nucleation substrate, promoting the refinement of 16.19 & micro;m to 4.94 & micro;m. Dense grain boundaries diluted the content of elements with low diffusion coefficients (Zn, Mg, and Cu), and the micron-sized second phases size in grain boundary segregation decreased from 1 & micro;m to 0.5 & micro;m. First-principles calculations indicated that Zn and Mg elements tended to aggregate at the Al3Zr/alpha-Al interface. Furthermore, the dislocation network surrounding Al3Zr promoted the precipitation of nanophases. Besides, the tensile strength and elongation of the welded joints increased to 407.11 MPa (72.7% of BM) and 4.79%, respectively. This work achieved the dual-scale second phases tuning by introducing the Al3Zr phases in the welded joint, providing guidance for fusion welding of high-strength aluminum alloys in practical applications.

Invar 36 alloy is an indispensable material for high-precision engineering. Herein, a synergistic CoCr co-alloying strategy via oscillating laser-Metal Inert Gas (MIG) hybrid welding (executed at 3000 W laser power, 140 A arc current, 150 Hz oscillation with 1.5 mm amplitude, and 21.6 mm/s welding speed) was proposed to balance this paradox. Subsequently, the microstructural, mechanical, and electrochemical properties of the joints were characterized by X-ray diffraction (XRD), energy-dispersive X-ray spectroscopy (EDS), electron backscatter diffraction (EBSD), tensile testing, and electrochemical measurements. Integrated experimental and DFT results demonstrate that the (Co + Cr) composite interlayer exhibits no elemental enrichment. This uniform state is thermodynamically supported by the calculated mixing enthalpy, which decreases from −1.84 kJ/mol for the base FeNi alloy to −2.11 kJ/mol for the composite matrix, indicating enhanced phase stability. The composite joint achieves a superior ultimate tensile strength of 436.85 MPa and an elongation to 38.80%, driven by intense solid-solution lattice distortion. Electronically, the synergistic coupling of Cr and Co maximizes the surface energy (3.75 J/m2) and work function (4.88 eV), constructing a highly capacitive passive film that expands the passivation span to 691.12 mV in chloride media. Experimental results and DFT calculations demonstrate that the (Co + Cr) composite maintains a thermal expansion coefficient similar to that of the base material. Three-dimensional thermo-mechanical finite element analysis indicates the evolutionary trend of the residual stresses. Specifically, the internal stress state of the joint with the composite interlayer is most similar to that of the joint without any interlayer, and it exhibits a lower residual stress level compared to the joints with single-element interlayers.

This study investigates the role of ring–beam power (Pr) in adjustable mode beam (AMB) laser welding of dissimilar 6061 Al alloy to DP590 steel, with a focus on the critical balance between porosity suppression and intermetallic compound (IMC) control. Unlike conventional lasers, AMB enables independent modulation of the center and ring beams, providing precise energy distribution essential for dissimilar joining. By integrating high–speed imaging and CFD simulations, we reveal that Pr governs keyhole stability and melt–pool convection. The results show that Pr = 600 W yields the highest mean shear force of 1067 N, with a recommended processing window of 500–700 W, within which mechanical performance is significantly improved over both lower and higher power conditions,the enlarged and stabilised keyhole effectively reduces porosity, while the formation of a ductile Fe3Al–rich layer enhances joint ductility and strength. However, when Pr exceeds 800  W, excessive turbulent mixing can lead to an excess of brittle Fe2Al5 and FeAl3 phases, triggering IMC-induced brittle cracking, severely degrading mechanical performance. This combined experimental–numerical approach provides a quantitative mechanistic framework for optimising Al/steel laser welding and clearly defines the allowable Pr window for achieving sound joints.

To obtain the desired microstructures in laser powder bed fusion 17-4PH stainless steel for multifunctional performance demands, this study optimised the microstructure and mechanical behaviour under extreme service conditions of elevated temperatures and high stresses. Solution temperatures were varied from 980 to 1220 degrees C to improve austenite and precipitate characterisation. The reverted austenite content initially increased and then decreased with increasing solution temperatures, peaking at 1040 degrees C, which corresponded to an optimal plasticity of 21.30% at room temperature. Cu-rich precipitates were slightly coarsened and preferentially distributed along grain boundaries at elevated solution temperatures. The increased internal stress enabled partial retention of the body-centred cubic structure, even in large-scale particles. The enhanced coherency promoted dislocation shearing mechanism, which provided a stronger strength contribution and overcompensated for the softening induced by coarsening. Consequently, samples with optimised solution temperature of 1160 degrees C exhibited an improved tensile strength of 1103.9 MPa at room temperature, and the high-temperature stress rupture life reached 630 h. The supersaturated matrix promoted the dynamic reprecipitation of dispersed fine needle-like coherent Cu-rich precipitates. The dual-scale strengthening structure and carbides enhanced deformation resistance, leading to a remarkable enhancement in the high-temperature stress rupture performance compared with the conventional heat treatment process.

This study investigates the influence of laser power on weld formation, microstructure, and mechanical performance of 6-mm-thick Q235B steel joints fabricated by laser-CMT hybrid welding, combined with finite element thermal simulations. Results showed that increasing laser power decreased the cooling rate and promoted grain coarsening in all weld regions. The WZ consisted mainly of FA, FSP, FP, and bainite; the CGHAZ was dominated by Widmanstatten; while the FGHAZ contained refined ferrite-pearlite compared with the BM. EBSD analysis indicated that higher laser power enhanced texture intensity, while the fraction of HAGBs decreased from 69.8 % to 54.2 % and the KAM value dropped from 0.68 degrees to 0.53 degrees, reflecting a reduction in geometrically necessary dislocation density. At 5100 W, the joint exhibited optimal properties, with tensile strength of 730 MPa, elongation of 13.12 %, strength-ductility balance of 9.6 x 103 MPa% and peak microhardness of 204.6 HV. These superior properties were attributed to defect-free weld morphology, moderate grain size, and a favorable balance of texture and grain boundary characteristics. Numerical simulations accurately reproduced thermal cycles and weld profiles, confirming that higher power extends cooling time and reduces cooling rate, thereby accelerating grain growth. Overall, appropriate heat input is essential for controlling microstructural evolution and achieving a superior strength-ductility synergy in laser-CMT hybrid welded joints.

Invar alloy is renowned for its ultra-low coefficient of thermal expansion and is widely employed in marine structures such as LNG containment systems. However, its relatively poor mechanical properties and the susceptibility of welded joints to corrosion in marine environments significantly compromise joint reliability. In this study, a novel approach was proposed by introducing a cobalt (Co) interlayer with different thicknesses during oscillating laser-MIG hybrid welding to simultaneously enhance the mechanical and corrosion properties of Invar alloy welds. The results demonstrated that the addition of Co effectively refined the weld grains. Under the combined agitation of the laser and arc, a relatively uniform distribution of Co was achieved. Among the investigated samples, the joint with a 0.6 mm Co interlayer exhibited the highest tensile properties. DFT calculations and tensile tests indicate that cobalt addition enhances the plasticity of the material, while deformation-induced strengthening further increases the ultimate tensile strength. DFT calculations further elucidated the underlying mechanisms, showing that Co reduced the surface energy of the (111) plane and stabilized the magnetic d-electrons of Fe atoms, thereby reducing their surface reactivity and improving surface stability and passive film resistance.

Direct glass-to-metal welding under non-optical-contact conditions is hindered by the large differences in thermal expansion and thermal conductivity between the two materials. In this work, aluminosilicate glass was joined to 304 stainless steel by nanosecond laser welding using an Al interlayer together with laser oscillation. The effects of interlayer thickness and oscillation amplitude on joint formation, interfacial evolution, and mechanical performance were systematically investigated. The optimum condition, consisting of a 20 μm Al interlayer and a 0.18 mm oscillation amplitude, yielded the highest shear strength of 17.9 MPa, whereas the interlayer-free joints showed only 4.2 MPa. The introduction of the Al interlayer enlarged the joining region, while a residual central pore still remained. When moderate oscillation was further applied, the large central cavity disappeared, the transition zone became wider and denser, and the fracture mode changed from interfacial brittle fracture to mixed fracture. The improved joint performance was therefore attributed to the combined effect of interlayer-assisted interface expansion and oscillation-promoted defect suppression. This study shows that matching the interlayer thickness with a suitable oscillation condition is an effective way to improve direct glass/metal welding under non-optical-contact conditions.

Integrating metals and polymers is pivotal for advanced functional applications, yet their intrinsic electronic bonding origin remains elusive due to material mismatch. Combining density functional theory (DFT) calculations and experiments, this study establishes a unified interfacial electron donor-acceptor framework. We demonstrate that interfacial metal oxides and polymer carboxyl groups facilitate μ₂-bridging coordination, driven by p-p σ hybridization between metal vacant 3p and oxygen lone-pair 2p orbitals, which is verified by valence band spectra. Furthermore, introducing surface oxygen vacancies enhances the electron-accepting capability of metal sites, enabling the coordinated interface to resist thermodynamic fluctuations, thereby improving the tensile-shear strength by over 400%. Cross-system validations across various cation valence states (+1 to +4) and polymer heteroatoms successfully demonstrate the general applicability of this theory-guided acceptor mechanism among diverse structural alloys and thermoplastics. This work provides a predictive electronic-structure foundation for the rational design of high-performance multi-material hybrid interfaces beyond specific systems.

Additively manufactured metastable β titanium alloys suffer from an inherent severe strength-ductility trade-off and inadequate corrosion resistance, originating from ultrafast solidification-induced nonequilibrium microstructures and high-density crystallographic defects. Conventional thermal post-treatments, relying on thermally activated atomic diffusion, lack the spatiotemporal precision to tailor defect architectures and inevitably cause grain coarsening, precluding synergistic optimization of mechanical and electrochemical properties. Herein, a single-step electropulsing treatment (EPT) strategy is proposed for laser additively manufactured Ti-10Mo-6Al-1.5Zr alloy, enabling concurrent modulation of α′ martensite crystallographic alignment and topological reconstruction of dislocation/stacking fault (SF) networks. After treatment at 150 A for 10 min, the alloy achieves 9.5% tensile elongation (2.5-fold increase over the as-deposited state) while retaining 1446 MPa ultrahigh ultimate tensile strength, with a 93% reduction in corrosion current density. HRTEM observations reveal that α′/β interface dislocation pileups induce intense local stress concentrations, triggering SF/deformation twin nucleation and sustained twinning-induced plasticity (TWIP) effect. Electrochemical measurements demonstrate that moderately regulated dislocations and SF crystallographic defects provide fast ion diffusion pathways in TiO2 passive films, accelerating their self-healing and inhibiting Cl− penetration. This work overcomes fundamental limitations of conventional thermal processing, opening a promising paradigm for integrated multi-property optimization in additively manufactured alloys.

This study investigates laser spot welding of a 0.06 mm thick spring layer baseplate onto a thin substrate, employing numerical simulation via Simufact Welding(2020 version). Validation of the numerical model revealed a strong agreement between simulated and experimental molten pool diameters, with a minimal deviation of 5.8 %. The optimal welding strategy for a single feather-shaped component demonstrated that fixtures reduced post-weld deformation by similar to 60 %, albeit with a 20 % increase in residual equivalent stress. Through an L9 (3(3)) orthogonal experiment, laser power, cooling time, and welding time were identified as critical parameters influencing deformation, with the optimal combination being 20 W laser power, 1.8 s welding time, and 30 s cooling time. Furthermore, welding sequence analysis showed that a counterclockwise approach minimized deformation by 36 % compared to the clockwise sequence, while orthogonal sequences reduced deformation by 28 % relative to conventional methods. These results offer practical insights for enhancing the dimensional stability and mechanical performance of ultra-thin component welding.

Existing research on microtextures predominantly concentrates on their wear-reducing effects on working surfaces and the associated influencing factors. However, comprehensively understanding of microtexture wear-reduction mechanisms remains elusive. Moreover, the effects of heat input and arrangement spacing on the formation quality of microtextures remains relatively shallow. This knowledge gaps hinder effective implementation of microtextures for wear reduction in practical applications, highlighting the need for further research. This study addresses the issue of excessive wear in the side-by-side gear assemblies of vehicle power systems. A novel wear-reduction strategy was developed that involves the use of laser technology to create microtextures on the end faces of a 38CrSi gear steel to enhance the load-carrying capacity of the lubricating oil, and thus mitigate gear wear. Initially, a mathematical lubrication model was constructed based on the Reynolds equation. This model analyzes the influence of the microtexture arrangement spacing on the pressure distribution of the lubricating oil film. Through meticulous calculations of the oil-film pressure distribution under various arrangement spacings, a significant finding emerged: reducing the microtexture arrangement spacing can effectively improve the load-carrying capacity of the oil film. Specifically, when designing wide-spaced microtextures, the optimal spacing should be below 0.30 mm, and for narrow-spaced ones, it should not exceed 0.15 mm. This discovery provides crucial theoretical guidance for optimizing the layout of microtextures. Subsequently, a series of process experiments were conducted by varying the microtexture arrangement spacing and scanning speed. The experimental results revealed that when the arrangement spacing was narrow, a large heat input caused mutual thermal interference owing to the overlap of the heat-affected zones. This interference disrupts the stability of the microtexture-forming process and prevents the formation of high-quality microtextures. However, a small heat input fails to meet the requirements for the depth and size of the microtextures, which are essential for their proper functioning. Laser scanning speed is crucial in microtexture preparation. A lower scanning speed led to significant remelting and backfilling of the metal deposition layer. This phenomenon affects the depth and shape of the microtextures, resulting in an irregular and less effective structure. Conversely, a higher scanning speed may cause insufficient heat input, leading to poor forming quality, such as incomplete microtexture formation or weak bonding with the substrate. Finally, an optimized microtexture preparation process is proposed. After thorough experimentation and analysis, the optimal laser texturing process parameters were determined. These parameters included a laser power of 160 W, a scanning speed of 10 mm/s, a pulse frequency of 95 kHz, 10 processing cycles, and an arrangement spacing of 0.3 mm. This optimized process effectively enhanced the lubrication performance of the surface of the gear steel, significantly reducing wear. It also demonstrates good adaptability in industrial applications and offers a practical solution for improving the durability of mechanical components. Additionally, this study provides a valuable reference for preparing microtextures on similar metal surfaces. This promotes the broader application and development of microtexture technology in diverse industries such as machinery manufacturing, where reducing friction and wear is crucial for improving the efficiency and lifespan of equipment, and aerospace, where component reliability under extreme conditions is crucial.

Oscillating/alternating magnetic fields have been proven to promote columnar-to-equiaxed grain transition (CET) in laser/arc welded joints, whereas the effectiveness of steady magnetic fields remains controversial. This study explored whether CET can be promoted by an external steady magnetic field in laser-MIG hybrid welding of aluminum alloy. Welds were produced at different magnetic flux densities; grain morphology and thermal-fluid flow were analyzed. The results showed that the steady transverse magnetic field interacted with the arc current to generate a backward Lorentz force in the rear molten pool, fracturing columnar dendrite tips and promoting CET. However, Joule heating induced by the magnetic field caused grain coarsening. This study will provide a more underlying understanding of weld grain growth dynamics.

An integrated approach of online monitoring and numerical simulation was employed to systematically analyze plume-induced energy attenuation and molten pool properties in narrow gap laser welding (NGLW) of 18 mm 5A06 plates, focusing on different laser beam oscillation patterns to enhance weld formation quality. Compared to laser welding without oscillation, circular oscillation was demonstrated to enhance molten pool and plume stability, reduce plume height and mitigate laser energy attenuation induced by the plume. Simulation results revealed that in NGLW without oscillation, the molten pool front exhibited flow patterns from both sidewalls toward the center due to lateral constraints, thereby destabilizing the molten pool. In contrast, the stirring effect generated by circular oscillation eliminated such constraints. It redirected the molten flow from the center toward the groove sidewalls, enhancing interfacial bonding between the filler material and sidewalls. Within a groove width range of 3-6 mm, welds free from lack-of-fusion (LOF) defects were consistently achieved when the laser amplitude was set at 2.4 mm.

During the laser welding process of 2xxx series aluminum alloys, the strength of the welded joint is significantly reduced by severe grain boundary segregation in the weld seam, thereby greatly impairing the service performance of the welded structure. The laser beam oscillation can be used to improve the solidification behavior of the molten pool, and effectively suppress grain boundary segregation in the weld seam. In this work, laser beam oscillation welding was applied on the joining of 2219 aluminum alloy plates, and the influence of oscillating patterns on grain boundary segregation in the weld seam was investigated. The experimental results indicated that the circular oscillating pattern shows the best suppression effect on grain boundary segregation in the weld seam. This is attributed to a more uniform temperature distribution in the molten pool promoted by laser beam oscillation. The non-equilibrium solidification phenomena can be significantly reduced, and the distribution of Cu elements in the joint is more uniform. The suppression of grain boundary segregation in the weld seam significantly enhances the joint strength, which increases from 217 to 273 MPa, corresponding to 85

This work proposed a hybrid surface pre-treatment method to enhance the laser joining strength of aluminum (Al) alloy/carbon fiber-reinforced thermoplastic composite (CFRTP) joint. This hybrid approach involved incorporating polyamide 66 (PA66) with Al particles as an interlayer at the Al alloy/CFRTP interface and introducing microtextures on the Al alloy. The influence of the interlayer thickness on the joining strength of texturing Al alloy/CFRTP was discussed. Results indicated that using this hybrid method increased the joining strength to approximately 153% compared to when no interlayer was used. A maximum joining strength of 22.7 +/- 0.4 MPa was achieved with a 69 mu m thickness interlayer. The interlayer used to fill deep microstructures improved thermal transfer and strengthened physical interlocking at the interface. With an interlayer thickness of 69 mu m, the resin filling rate reached 100%, and the interfacial temperature peaked at 373 degrees C, which was 34 degrees C higher than that without an interlayer. The digital image correlation (DIC) results confirmed the strain of the joint was decreased. Additionally, the improved salt spray corrosion resistance and fatigue performance demonstrated the potential of this approach for broader engineering applications.

Thermal accumulation phenomenon occurs during the continuous layer-by-layer manufacturing process of components fabricated via Laser Directed Energy Deposition (LDED), which leads to issues such as deteriorated forming performance. Molten pool temperature can well reflect thermal accumulation during manufacturing, molten pool fluidity, as well as influence post-manufacturing forming and performance characteristics. This paper presents a simulation-driven, restart-enabled laser power planning strategy for the regulation of molten pool temperature during the laser directed energy deposition process. Through numerical simulations, the spatial distribution of laser power has been optimized to avoid thermal accumulation during the printing process. This strategy employs two incremental PI controllers incorporating a restart mechanism, which uses iterative feedback within the finite-element simulation to generate a precomputed, position-dependent laser power schedule to achieve precise control over the molten pool temperature. This numerical model-based deposition strategy can not only control the temperature value around the target value but also realize flexible control of temperature fluctuations according to different production requirements. A comparison was conducted on the molten pool temperature, forming quality, and mechanical properties of IN718 superalloy deposited under the two modes (the simulation-planned variable-power deposition and conventional constant-power deposition). For the investigated IN718 thin-walled structure, the control mode reduced the top-region surface roughness from 27.87 ± 1.11 μm to 13.58 ± 0.89 μm and decreased the representative substrate warpage angle from 2.9° to 1.9° compared with the conventional mode, while maintaining higher average tensile strength. These results indicate that the simulation-planned laser power profile can mitigate heat accumulation and improve the macroscopic forming quality of the deposited thin-walled structure.