Laser–arc hybrid welding (LAHW) is an advanced welding technology that integrates both laser and arc heat sources within a single molten pool, achieving synergistic benefits that surpass the sum of their individual contributions. This method enhances the welding speed and depth of the fusion, stabilizes the process, and minimizes welding defects. Numerous studies have investigated the principles, synergistic effects, keyhole dynamics, joint performance, and various factors influencing the parameters of laser–arc hybrid welding. This paper begins with an introduction to the classification of LAHW, followed by a discussion of the characteristics of gas-shielded welding, argon arc welding, and plasma hybrid welding. Subsequently, the welding principles underlying laser–arc hybrid welding will be elucidated. To enhance weld integrity and quality, this paper will analyze keyhole behavior, droplet transfer dynamics, welding quality performance, and the generation and prevention of welding defects that affect laser–arc hybrid welding. Additionally, a detailed analysis of the effects of residual stress on the shape, microstructure, and phase composition of the weld will be provided, along with an exploration of the influences of various welding parameters on post-weld deformation and mechanical properties.

This study systematically investigates the behavior of droplet transfer and the characteristics of weld morphology in laser-cable-type welding wire (CWW) arc hybrid welding under varying Ar-CO₂ shielding gas compositions, utilizing AH36 shipbuilding steel. During the hybrid welding process, a comparative analysis was conducted on the welding process and weld formation using a high-speed camera system and a current–voltage waveform acquisition system. The experimental findings indicated that the arc width exhibited an upward trend, while the arc height demonstrated a decline as the CO₂ content increased. Additionally, the welding current experienced a decrease. Furthermore, the arc became more regular with an increase in the top arc width, which enhanced process stability. The peak intensity of the curve for 90% Ar + 10% CO₂ was the largest, and the peak range was the narrowest, indicating that the current was more stable compared to the other two shielding gas compositions. The droplet transfer frequency exhibited a decreasing trend with the increase in CO₂, while the diameter initially decreased and then increased. As the CO₂ content increased, the droplet transfer mode transitioned from a mixed mode involving both globular transfer and short circuits to predominantly globular transfer. The increase in CO₂ promoted weld penetration while reducing its width, with the penetration depth of the weld increasing by 12.3% when the CO₂ content rose to 18%.