To develop in-depth understanding of metallurgical phenomena for completeness, mechanical heterogeneity is kinetically and thermodynamically explained by thorough microstructure characterization of engineering materials, e.g. polycrystalline nickel-based superalloy, for alleviation of weldability-related problems during laser-induced keyhole fabrication. Because of nonequilibrium solidification behavior inside weld pool, finer γ phase dendrite substructure is confined to partition-resistant keyhole bottom part, coarser dendrite is crystallography-independently circumscribed at partition-vulnerable neck transition region of full penetration weld, and thus microstructure is lack of homogeneity. Abundance of segregation-driven eutectic phase or intermetallic phase in the interdendrite area throughout weld is essentially attributable to nonequilibrium solidification conditions, and morphologically increases susceptibility to mechanical properties deterioration. As a result of γ phase instability, Niobium-aided Laves/γ eutectic reaction in the vicinity of dendrite interstices at terminal stage of solidification contributes to severe dendrite boundaries brittleness, impairs mechanical properties, which is consistent with metallography and fractography results, and is more deleterious to weldability, since solute redistribution and supersaturation adversely exacerbate segregation behavior in the residual interdendrite liquid, especially asymmetric weld pool shape. There is inverse parabolic relationship between secondary dendrite arm spacing and solute partition coefficient, when location varies from nail-shaped weld upper site to bottom site. Chemical, microstructural and mechanical heterogeneities are more geometrically favorable in the curvature-related neck transition region. In addition, the mechanism of thermal, metallurgical and mechanical inhomogeneities, which are attributed to asymmetric weld pool shape, is consequently proposed. Untoward metallurgical phenomena, such as microstructure heterogeneity and brittle Niobium-rich Laves/γ eutectic phases mitigate strength, ductility and toughness of weld. In order to macroscopically and microscopically satisfy superior mechanical properties requirement, chemistry and microstructure of high quality weld are metallurgically controlled. Fruitful metallurgical information and mechanical data further support the reasonable explanations. It is imperative to progressively advance welding metallurgy, weldability and fabricability of intricate shape for welding defects minimization, suppress segregation and further develop mechanical properties through viable design and control of laser processing, simultaneously.
