From Microstructure to Mechanical Performance: Characterization of Similar and Dissimilar Welds in Cast, Wrought, and LPBF Aluminum Alloys

Hybrid lightweight structures increasingly combine cast, wrought, and additively manufactured aluminum alloys, but the mechanical response of their welded joints remains strongly material-dependent. In this study, cast EN AC-42100-T6, wrought EN AW-6082-T6, and laser powder bed fusion (LPBF) AlSi10Mg stress-relieved plates were welded in 4 and 8 mm configurations using cold metal transfer and pulsed multi-control processes over two campaigns. Weld defects, microstructure, hardness profiles, and tensile properties were analyzed using a framework combining a hardness derived local yield-stress descriptor (σ_y,loc), a cumulative hardness deficit (ID_HV), and a porosity increment metric (ΔP). The second campaign eliminated fusion and penetration related defects, but did not mitigate fusion zone porosity in LPBF-related joints, which reached 13.7% in the 8 mm LPBF–Cast joint. Hardness analysis showed the widest hardness-affected region in the wrought alloy, an intermediate response in the cast alloy, and localized alteration in LPBF. Tensile results identified three degradation modes: strength loss associated with heat-affected zone (HAZ) softening in wrought-containing joints, ductility limitation associated with the initial cast condition, and porosity-associated ductility loss in LPBF-related joints. The lower yield strength reduction in LPBF-related joints does not imply improved performance, as fracture remains strongly influenced by fusion zone porosity. The results support material specific mitigation and design strategies for hybrid welded aluminum structures.