There are many problems in the arc welding repair of aluminum alloy parts, such as excessive pores, coarse grains, and low hardness. Introducing external energy excitation is an effective solution. In this paper, 7075 aluminum alloy parts are repaired using the arc welding - laser shock forging technique. The effects of laser-wire spacing, laser pulse energy and frequency, welding current and speed, and V-groove depth on the surface morphology, section geometric characteristics, and porosity of the repaired layer are studied. Additionally, the hardness and microstructure of the repaired layer formed by arc welding - laser shock forging and arc welding are compared. The results show that a fine surface morphology of the repaired layer can be achieved by selecting reasonable laser-wire spacing, welding current, welding speed, and V-groove depth. It is also advised to select the maximum laser pulse energy and frequency possible, in order to increase the aspect ratio, reduce the residual coefficient, minimize porosity, and decrease the maximum pore diameter of the repaired layer. When compared to arc welding alone, arc welding - laser shock forging has the advantage of reducing grain size and improving the hardness of the repaired layer.

The FGH95 superalloy used for turbine disk manufacturing was strengthened by the oblique laser shock processing (OLSP). The laser energy, beam diameter, and number of impacts were selected as the test factors, and the three-factor three-level oblique laser shock processing orthogonal test was carried out. Based on the analysis of variance and range of the surface residual stress, microhardness, roughness, tensile strength, and yield strength of FGH95 superalloy after LSP, the factor level combination of relative best comprehensive performance was obtained. The results showed that, within the 10% confidence level, the order of influencing factors with significant difference is: laser energy > number of impacts > beam diameter. Compared with the unimpacted sample, the microhardness of the material surface was increased by about 25% after OLSP. With the increase of laser energy, the dimple distribution of the sample was more uniform, smaller in size, and shallower in depth. However, the thickness of the affected layer was very low, and there was no significant effect on the tensile properties. In general, and under the test conditions selected in this study, the combination of 8 Joule laser energy, 3 mm beam diameter, and three impacts can be selected to obtain the best comprehensive performance. The results of this paper provide a reference for the OLSP of the FGH95 superalloy turbine disk and other aero engine parts.