Laser Wire Research Articles

Influence of annealing on microstructures and mechanical properties of laser powder bed fusion and wire arc directed energy deposition additively manufactured 316L

The annealing response of 316L stainless steel manufactured with both laser powder bed fusion (PBF-LB) and wire-arc directed energy deposition (DED-Arc) was investigated in the context of microstructural evolution and mechanical properties. Because additive manufacturing (AM) comprises several technologies that differ in heat source, feedstock, and scan strategy, among other build variables, the final products can experience a range of thermal histories and defect (dislocation) populations. These unique thermal histories can subsequently influence as-built properties and annealing response of AM materials, most notably those manufactured with different AM deposition processes. The PBF-LB process (with higher cooling rates) yielded finer austenite microstructures having more lattice strain, higher dislocation densities, and higher yield strength values than the DED-Arc 316L process (with lower cooling rates). Electron backscattered diffraction (EBSD) data of the kernel average misorientation (KAM), boundary density, and geometrically necessary dislocation (GND) density support the differences in lattice strain. As a result, the PBF-LB 316L exhibited more recovery and recrystallization after annealing at elevated temperatures above 873 K based on changes to yield strength, work hardening behavior, and microstructure evolution. The DED-Arc 316L exhibited a δ-ferrite/austenite microstructure with microsegregation that influenced deformation mechanisms active after annealing. Tensile data, deformed microstructures and misorientation histograms from EBSD showed a decreasing amount of deformation twinning when comparing the as-built condition to annealed conditions (up to 1473 K/1h) of PBF-LB 316L. The opposite trend was noted in DED-Arc 316L. The behavior was interpreted to be due to the differences in chemical segregation during solidification and the effects of heat treatment on chemical homogenization and local stacking fault energy.

Theoretical modeling of feedstock-laser energy interaction in directed energy deposition with simultaneous wire and powder feeding

The Laser-based Directed Energy Deposition (L-DED) process is widely employed for the fabrication of numerous metallic parts. It also stands out as a crucial additive manufacturing (AM) technique for creating metal matrix composites (MMCs) reinforced with ceramic particles. The simultaneous deposition of wire and powder feedstocks into the created melt pools on the substrate surface proves advantageous in overcoming the limitations associated with mixed powders in powder deposition alone. The strategy of coaxial wire and powder deposition (CWP-DED) allows for more efficient construction of MMCs with complex geometries and desirable properties. Nevertheless, CWP-DED is a complex multi-phase deposition process that involves highly dynamic interactions among laser beams, wire, and powder particles, influencing laser energy distribution and absorption during the process. This work aims to develop a theoretical model to advance the fundamental understanding of the absorbed and lost laser beam energy by the fed wire and powders in CWP-DED before entering the melt pool. Laser energy absorption coefficients can be calculated based on the Step Wise Heating method to determine the final temperature of the powder particles and wire before entering the melt pool. The experimental validation of the proposed model requires a power meter that fits the CWP-DED system with six inclined laser beams, which is not commercially available so far, to measure the actual output power with and without wire and powder feeding. Consequently, this work presents a detailed explanation of the experimental procedure desired to measure the absorption coefficients of the wire and powder feedstocks and how to validate the proposed model as a future research endeavor. This model plays a vital role in predicting and understanding the amount of heat transferred into the melt pool, which lays a foundation for understanding the complicated melt pool thermodynamics that directly govern the microscopic characteristics and macroscopic properties of the as-built parts.

Location-Dependent Phase Transformation Kinetics During Laser Wire Deposition Additive Manufacturing of Ti–6Al–4V

This work models the microstructural evolution as a function of position in laser-wire deposited Ti–6Al–4V parts using a classical multi-component JMAK nucleation and growth model with additive isothermal time-steps. Model predictions are compared to experimental observations. The model can be used to interpret nucleation and growth kinetics of various characteristic features of the microstructure that are inaccessible by experiments. It explains the presence of “layer bands” at specific locations unrelated to the weld bead structure. The last re-heating (of multiple thermal cycles) of a solidified layer, and where it peaks, plays a key role in increasing the nucleation density at specific locations, resulting in full α\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\alpha $$\\end{document}-colony microstructures constituting the “layer bands,” while the rest of the build is predominantly basketweave. Additionally, changes in the basketweave α\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\alpha $$\\end{document}-lath thickness as a function of the distance from the substrate are studied and compared with an Arrhenius-type function, with results highlighting a more complex relationship than an Arrhenius-type function would suggest.

Analysis of thermal behavior and mass transport for manufacturing deep-small hole by ultra-high frequency induction-assisted laser wire deposition

Synchronous ultra-high frequency (UHF) induction-assisted laser deposition is an effective approach to tackle the extreme heat input and common defects that originate from laser direct deposition. The added auxiliary induction heat source can reduce the energy input of the laser heat source which guarantees the geometric integrity of the embedded tube and decreases temperature gradient. Meanwhile, the effective preheating of the induction heat source assures the metallurgical bonding among the substrate, deposited track and embedded tube. Experiments showed that the effective bonding can be formed among substrate-deposited track and deposited track-embedded tube under suitable combination parameters of the laser heat and induction heat. To gain insight into the hybrid deposition, a 3D numerical model coupled with multi-physical fields was established to explore the thermal process and flow behavior with assistance of induction heat. Results indicated that the electromagnetic force produced by induction coil promotes the flow velocity, which increases heat convection. Investigation on the induction heat parameter demonstrated that raising current intensity can accelerate the flow velocity from 0.07 m s-1 to 0.09 m s-1 while the maximum temperature of the molten pool declined from 2610 K to 2440 K owing to the reinforced heat convection. The experimental cross-section of the deposited tracks and the detected element distribution in transition areas are well tested against the numerical simulation results. The grain size in the top region of the deposited track is refined with increasing current intensity, which is experimentally and numerically verified by observed microstructure and G*R value. Meanwhile, the fabricated deposited track with average friction coefficient of 0.445 can be obtained when the laser and induction parameters are 1000 W and 400A, respectively.

Dynamic and quasi-static strength of additively repaired aluminum

Additive manufacturing has the potential to repair high value components, saving significant time and resources; however, the level of reliability and performance of additive repairs is still relatively unknown. In this work, the structure–property and performance of laser wire additive manufacturing repairs in 1100 aluminum are investigated. Two types of intentional damage are inflicted on the samples and subsequently repaired with pulsed laser deposition additive manufacturing. Quasi-static (10−3s−1) and high strain-rate (10−3s−1) mechanical testing is carried out with in situ diagnostics and post-mortem imaging. The results show that while the quasi-static strength and ductility of samples with a repaired region are lower than a pristine sample, the dynamic strength under shock loading is comparable. This work highlights both the potential utility of additive manufacturing for repair purposes, the significant risk of compromised performance of additive parts under specific conditions, and the need to test at varying strain rates to fully characterize material performance.

Process mapping and anomaly detection in laser wire directed energy deposition additive manufacturing using in-situ imaging and process-aware machine learning

This work concerns the laser wire directed energy deposition (LW-DED) additive manufacturing process. The objectives were two-fold: (1) process mapping – demarcating the process states as a function of the processing parameters; and (2) process monitoring – detecting process anomalies (instabilities) using data acquired from an in-situ meltpool imaging sensor. The LW-DED process enables high-throughput, near-net shape manufacturing. Without rigorous parameter control, however, LW-DED often introduces defects due to stochastic process drifts. To enhance scalability and reliability, it is essential to understand how LW-DED parameters affect processing regimes, and detect deleterious process drifts. In this work, single-track experiments were conducted over 128 combinations of laser power, scanning velocity, and linear mass density. Four process states were observed via high-speed imaging and delineated as stable, dripping, stubbing, and incomplete melting regimes. Physically intuitive meltpool features were used to train simple machine learning models for classifying the process state into one of the four regimes. The approach was benchmarked against computationally intense, black-box deep machine learning models that directly use as-received meltpool images. Using only six intuitive meltpool morphology and intensity signatures, the approach classified the LW-DED process state with statistical fidelity approaching 90 % (F1-score) compared to F1-score 87 % for deep learning models.

Microstructural characteristics and mechanical properties of Al-Cu alloys fabricated via 8-shaped oscillating laser wire additive manufacturing

Al–Cu alloy components fabricated by laser wire additive manufacturing (LWAM) generally present coarse columnar grains and poor mechanical properties. This study proposes a new strategy, integrating an 8-shaped beam oscillation and laser directed energy deposition, to solve these issues. The impacts of oscillation frequencies and amplitudes on the energy flux distribution and macro morphology of the single-bead deposited layer are investigated. The influences of beam oscillation on the microstructural characteristics and tensile properties of Al–Cu alloys fabricated by oscillating laser wire additive manufacturing (O-LWAM) are revealed. A high-frequency oscillating laser achieves a uniform energy flux distribution and improves the surface quality of the deposited layer. The <100> texture in the O-LWAM specimen decreases markedly owing to the columnar to equiaxed transition. The Cu element content at grain boundaries in the O-LWAM specimen is reduced by 52.6 %. The ultimate tensile strength of O-LWAM specimens in the horizontal and vertical orientations reach 334.2 and 327.3 MPa, respectively, which increased by 40.7 % and 64.6 % compared to those of the LWAM specimen. The substantial enhancement in strength and plasticity is attributed to fine-grain strengthening.

Gap bridging in laser welding of EN AW 5083 with different joint configurations via beam oscillation and filler wire

The extended use of laser welding in the industry requires a less sensitive process in terms of geometrical tolerances of the joint edges. As the industrial availability of laser systems increases, the demand to use laser welding technology possibly with parts coming from less precise production steps is increasing. Gap formation is often caused by the edge quality of the parts coming from previous manufacturing steps such as sheet forming. Al alloy sheets deformed to box-shaped 3D forms often require welded joints on the edges in lap, but, and corner joint configurations. These joints are hard to carry out by laser welding due to the large gap formation caused by the tolerances of the deformation processes involved. Laser welding of Al alloys is already challenging in the absence of gap formation, while these joint configurations have been not feasible with a stationary beam due to incomplete fusion and defect formation. Laser welding with beam oscillation and wire feeding can improve the weldability of these joints. The oscillating motion of the high-intensity beam can achieve a deep weld together with a wider seam. Combined with wire feeding, the process can close gaps in the butt, lap, and corner joint configurations. On the other hand, the added oscillation and wire-related parameters require extending the experimental space, which requires a methodological study to identify feasible conditions. Accordingly, this work proposes a methodological approach to identify and set laser welding process parameters with beam oscillation and wire feeding for an EN AW 5083. Process parameters were initially studied using a simple analytical model that depicts the beam trajectory. Bead-on-plate tests were conducted to assess beam size, power, and weld speed ranges. Lap, butt, and corner joint conditions with a 0.5-mm gap were welded with high quality by manipulating the laser power, oscillation amplitude, and wire feed rate. The results show that welding speeds could be maintained as high as 55 mm/s with complete filling of gaps of up to 0.5 mm, eliminating the surface undercuts and achieving weld widths in the order of 2.5 mm. Moreover the results show the possibility control the depth of the welds from 3 mm to full-penetration conditions.

Experimental study and parameter optimization of laser wire additive manufacturing of titanium alloy

In the single-pass multilayer deposition process of laser wire additive manufacturing, variations in process parameters significantly influence the morphology of the deposited layer. This study experimentally investigates how the main process parameters (laser power, scanning speed, and wire feeding speed) affect the morphology of the deposited layer. It was found that each parameter has distinct effects on the geometrical morphology of deposition. Simultaneously, aiming to enhance the surface topography of the deposited layer and its bonding with the substrate, three optimization objectives are defined. An optimization model is then constructed using experimental data to refine the process parameters. The optimal parameters are determined through experimentation, resulting in significant enhancement of the deposited layer’s topography.

Effect of manganese on grain morphology and microstructure of Ti-6Al-4V alloy by laser wire deposition

The addition of growth restricting elements in additive manufacturing of Ti and Ti-based alloys can result in the formation of equiaxed structures. However, an excessive incorporation of these elements frequently impairs the mechanical properties. Obtaining the minimum necessary amount of addition is crucial to achieve the transition from columnar to equiaxed microstructure. This ensures that the desired equiaxed structure is obtained while minimizing any potential negative effects on the material's properties. Here manganese was taken as the potential grain refiner in Ti alloy. Then, evolutions of grain morphologies and microstructures as well as the mechanical properties various of Ti-6Al-4V alloy in laser wire deposition additive manufacturing with the growth restriction factors of 26, 32, 39 were explored respectively. And the average hardness of the deposits were 495 HV, 512 HV, and 530 HV, respectively, showing an increase of approximately 15%, 19% and 23%. When the growth restricting factor value reached 39, the columnar prior β grains underwent a complete transformation into equiaxed grains. Mn elements promoted the decomposition of β→α+Mn2Ti during the multi-pass deposition and the microhardness of the deposits were significantly increased. Additionally, Mn elements were expelled outwards during the β→α transition. Nevertheless, the diffusion rate of Mn elements was low and thereby there was a low growth rate of α phases, thus refining α phases.

Microstructure and fracture toughness of laser wire deposited Ti-6Al-4V

In this paper, the microstructure, and mechanical properties of Ti-6Al-4V fabricated through Laser Directed Energy Deposition (L-DED) process are investigated and discussed. Deposited coupons were produced on Ti-6Al-4V wrought substrate using Ti-6Al-4V ELI grade wire with the laser wire deposition (LWD) process. Characterization efforts led to the evaluation of the microstructure, hardness, tensile behavior, and fatigue crack growth resistance of the build-up alloy. Microstructure of the deposit consists of columnar prior β grains and basket-weave α/β phase mixture. The size of the alpha laths is measured as 1.2 ± 0.3 µm and 0.8 ± 0.2 µm in the banded zone and band-free zone, respectively. Hardness of the deposited block is found to be uniform and ranging between 321 and 323 Hv. Tensile and fatigue crack growth properties of the deposited block were evaluated in various orientations. Tensile specimens loaded in the deposition direction exhibited 824 MPa and 930 MPa for yield and ultimate tensile strength, respectively. Tensile specimens loaded in the build direction exhibited 782 MPa and 907 MPa for yield and ultimate tensile strength, respectively. The analysis reveal that the tensile properties of the deposited material match the strength requirements for ASTM F1108 Cast Ti-6Al-4V. However, they fell just below the AMS 4911P Wrought Ti-6Al-4V standard. Fatigue Crack Growth Rate tests were conducted for three directions: parallel to the deposition direction, parallel to the build direction and at 45° of the deposition direction. No significant differences in crack growth properties were observed between the different orientations with average crack initiation near threshold (ΔKth) and the fracture toughness (Kc) value of 3.6 MPa√m and 69 MPa√m, respectively. The crack propagation properties are similar to cast & wrought materials.

Role of layer arrangement in microstructure and corrosion behavior for 78-mm thick-plate 316L stainless steel fabricated via narrow gap laser wire filling welding

Controlling repeated thermal cycling is one of the key mechanisms to design microstructures in the interlayer regions for narrow gap laser wire filling welding (NGLWFW) of austenite stainless steels. Herein, the optimization of process parameters for individual layers is tailored to customize the molten pool morphology during the NGLWFW process, facilitating precise control over the microstructure and, consequently, enhancing both mechanical properties and corrosion resistance of the joint. The results showed that the molten pool morphology acquired by simulation are obviously diverse from the bottom zone (BZ), middle zone (MZ) to upper zone (UZ) of the welded joint ascribed to the high heat accumulation effect, leading to the variation of microstructure. At BZ, the combination of smaller grain size and reduced dendrite spacing reduce the number of corrosion sites and promote the formation of a denser and more uniform corrosion product layer. Additionally, the diverse grain orientation, characterized by lower texture strength, facilitated a more uniform distribution of elements. Furthermore, the significantly higher content of δ-ferrite showing smallish shape disrupted the directional growth of austenite columnar grains, contributing to the excellent corrosion resistance observed at the BZ.

Effect of Ni content on 475°C embrittlement of directed energy deposited duplex stainless steel using a laser beam and wire feedstock

Duplex stainless steel (DSS), specifically the 2209 grade, is increasingly employed in additive manufacturing, particularly in processes like directed energy deposition using a laser beam with wire (DED-LB/w). However, a significant challenge arises when DSS faces brittleness within the temperature range of 250–500 °C. This study employs advanced characterization techniques, including atom probe tomography (APT) and transmission electron microscopy (TEM), to investigate DSS embrittlement after aging at 400 °C for up to 1000 h. The hardness analysis revealed that the higher Ni content in DED-LB/w-fabricated DSS cylinder promotes the age hardening compared to 2205 wrought DSS plate. Furthermore, APT and TEM demonstrated that, alongside the decomposition of ferrite into Fe-rich (α) and Cr-rich (αʹ) phases, clustering of Ni, Mn, and Si atoms contributes to the embrittlement. Although the Ni-Mn-Si-rich clusters could suggest nucleation of G-phase, the G-phase crystal structure was not observed by TEM. This might be attributed to the short aging time or limitations in the characterization technique. This work underscores the impact of characterization techniques on the measurement of spinodal decomposition, with APT providing capability of detecting nanometer sized clusters. By elucidating the complexities of 475 °C-embrittlement in DED-LB/w DSS, this study offers valuable insights for industrial applications and a deeper understanding of age hardening in duplex DSSs under specific manufacturing conditions.

Effect of laser oscillation mode on LWAM deposition morphology and melting pool fluctuation

To investigate the impact of laser beam oscillation on melting pool fluctuation and deposition morphology during laser wire additive manufacturing, we observed transient melting pool fluctuations and measured the 3D deposition morphology. The study revealed that periodic beam oscillation enhances solution stirring, resulting in pronounced fluctuations in the melting pool and reduced roughness of the deposited surface. Furthermore, it was found that different laser oscillation modes resulted in different deposition morphologies. The shape of the melting pool is influenced by energy distribution characteristics, while the movement path of the spot determines this distribution. Moreover, the addition of beam oscillations effectively disperses the energy of the laser heat source, thereby mitigating the protrusion of the molten pool bottom.

Exploring the Friction and Wear Mechanisms of Nickel Titanium Alloy Fabricated by Laser Powder and Wire-Based Directed Energy Deposition

The NiTi alloy has attracted significant interest owing to its notable wear and corrosion resistance, suggesting the significant promise of utilizing additively manufactured NiTi alloys in tribological applications. In this study, dry sliding wear tests with sliding velocity of 0.1 m/s for total distance of 250 m at room temperature, 50 °C, 100 °C, and 200 °C were carried out on samples of NiTi alloy samples fabricated using laser powder and laser wire directed energy deposition (LP-DED and LW-DED) processes. Enhanced friction and wear behavior of LP-DED samples were captured at lower temperatures due to higher hardness and the stable dominating NiTi B2 austenite phase in the sample microstructure as confirmed from x-ray diffraction (XRD) analysis. Accumulated transferred material at lower temperatures played a crucial role in modifying the wear mechanisms. However, at higher temperatures both LP-DED and LW-DED samples presented similar wear mechanisms.

A Laser-Induced TIG Arc Narrow-Gap Welding Technique for TC4 Titanium Alloy Thick Plates Based on the Spatial Position Control of Laser, Arc and Filler Wire

In this paper, a novel laser-induced TIG arc narrow-gap welding technology is proposed for thick plates of TC4 titanium alloy. The feasibility of achieving high-performance welding joints is investigated by adjusting the spatial deviation position of the laser, arc, and filler wire. The results exhibited remarkable capabilities. By augmenting the laser-arc malposition, a stable deflection of the arc can be achieved, resulting in enhanced heat input to the sidewall adjacent to the laser side and improved fusion capability. Moreover, an inclined weld can be obtained through increased malposition between the filler wire and arc, which helps to improve interlayer fusion and suppress porosity defects. This method, involving alternating bilateral offsets between passes, successfully achieved narrow-gap welding of 24 mm-thick TC4 titanium alloy with an average tensile strength of 880.68 MPa (equivalent to 95.05% of base material strength). Therefore, this technology exhibits promising potential as an automated welding technique for achieving high-quality narrow-gap welding in titanium alloys.

Solidification behavior and texture of 316L austenitic stainless steel by laser wire directed energy deposition

The solidification behavior and crystallographic texture of 316L austenitic stainless steel builds fabricated via laser-wire directed energy deposition additive manufacturing (AM) were investigated. Shielding gas set-up and build type (single-track vs. multi-track) were varied, which led to changes in the solidification conditions and the final build compositions. Primary δ-ferrite solidification is predicted based on equilibrium thermodynamic predictions of the bulk feedstock composition. However, the increased solidification velocity of the AM process promotes a solidification mode transition from primary δ-ferrite to primary austenite. Skeletal δ-ferrite and lathy δ-ferrite associated with primary δ-ferrite solidification and interdendritic δ-ferrite associated with primary austenite solidification were observed among the laser-wire directed energy deposition walls. Skeletal and interdendritic δ-ferrite exhibited a (001)δ // (001)γ parallel relationship with austenite and a {001} solidification texture aligned with the build direction for both austenite and δ-ferrite. Lathy δ-ferrite exhibited a Kurdjumov-Sachs orientation relationship, (101)δ//(11¯1)γ, with austenite due to austenite nucleation in the solid-state. It is shown that the solidification behavior of AM 316L is accurately represented by as-built composition data and a dendrite growth model, which combined, encompasses the compositional and solidification condition impacts on the solidification pathway.

Microstructure evolution and property of high manganese steel coatings by laser shock assisted laser wire cladding

Field-assisted laser cladding (FALC) overcomes the limitations of laser cladding through the inherent advantages brought about by the use of various auxiliary energy fields (AEFs). Laser wire cladding (LWC) is limited by the common problems of laser cladding but has a promising future due to the extremely high material utilization rate. In this study, a laser shock assisted laser wire cladding (LSALWC) manufacturing process was proposed. In situ laser shock was introduced into the LWC to obtain finer grains structure and improve product performance. LSALWC does not change the composition of the coating, does not require the use of pretreatment and post-treatment, and does not reduce the efficiency of production. Using high manganese steel (HMS) as the model alloy, LSALWC was employed to achieve the expectation of reducing the proportion of columnar grains, refine the microstructure of columnar grains, and transform columnar grains into equiaxed grains. Compared with the sample (LC) manufactured by LWC, the performance of the sample (LSA) manufactured by LSALWC has been improved, the hardness increased from 285 ± 5 HV0.5 to 303 ± 6 HV0.5, the volume wear rate decreased from 2.1 × 10−4 mm3/N·m to 1.7 × 10−4 mm3/N·m, the primary dendrite spacing of the coating was reduced by 11.5%, and the heterogeneity of coating was more obvious. The cladding process under laser shock was studied using a high-speed camera, and the influence of laser shock on the coating was explained. The mechanism of the performance improvement of the LSA sample was explained. This study showed the disturbance of the molten pool was enhanced by laser shock, and the dendrites at the bottom were deflected or even broken. The broken dendrites were dispersed with the liquid flow and became new nucleation sites. Laser shock increased the supercooling during solidification by reducing the temperature gradient in the molten pool, and created an environment conducive to grain nucleation and growth. This process mitigates various issues in the casting process of HMS and provides a novel method for regulating the grain and microstructure of laser cladding. This research delves into the coupling between the AEF and the dynamic behavior of the molten pool, culminating in a model depicting the evolution of laser cladding solidification under the influence of the AEF, which will provide a new perspective for the research of FALC.

Hot corrosion behavior analysis and diffusion equation construction based on laser wire additive manufacturing GH3039

Laser wire additive manufacturing GH3039 samples with different process parameters are prepared. Then, hot corrosion test (Na2SO4+NaCl at 900 °C) is carried out. High power (5000 w), parallel to the deposition layer interface processing sample has good hot corrosion resistance due to the excellent internal organization. Element diffusion is the main factor affecting the hot corrosion performance. The element diffusion equation based on the multi-reaction interface is established and the degree of hot corrosion reaction can be directly judged. At the same time, the concept of determining the degree of hot corrosion reaction and predicting the trend of reaction by means of sulfides is proposed.

Research on the Low-Temperature Impact Toughness of a New 100-mm Ultra-Thick Offshore Steel Fabricated Using the Narrow-Gap Laser Wire Filling Welding Process.

Ultra-thick offshore steel, known for its high strength, high toughness, and corrosion resistance, is commonly used in marine platforms and ship components. However, when offshore steel is in service for an extended period under conditions of high pressure, extreme cold, and high-frequency impact loads, the weld joints are prone to fatigue failure or even fractures. Addressing these issues, this study designed a narrow-gap laser wire filling welding process and successfully welded a 100-mm new type of ultra-thick offshore steel. Using finite element simulation, EBSD testing, SEM analysis, and impact experiments, this study investigates the weld's microstructure, impact toughness, and fracture mechanisms. The research found that at -80 °C, the welded joint exhibited good impact toughness (>80 J), with the impact absorption energy on the surface of the weld being 217.7 J, similar to that of the base material (225.3 J), and the fracture mechanism was primarily a ductile fracture. The impact absorption energy in the core of the weld was 103.7 J, with the fracture mechanism mainly being a brittle fracture. The EBSD results indicated that due to the influence of the welding thermal cycle and the cooling effect of the narrow-gap process, the grains gradually coarsened from the surface of the welded plate to the core of the weld, which was the main reason for the decreased impact toughness at the joint core. This study demonstrates the feasibility of using narrow-gap laser wire filling welding for 100-mm new type ultra-thick offshore steel and provides a new approach for the joining of ultra-thick steel plates.