Butt welding tests of 1.5 mm thickness Ti–6Al–4V were treated by conventional gas tungsten arc welding (C-GTAW) and ultrahigh frequency pulse GTAW (UHFP-GTAW). The low cycle fatigue (LCF) experiments were conducted on the welded joints. The results of fatigue experiment showed that the number of fatigue cycles was increased with UHFP-GTAW. Changes in the microstructure resulting from reduced heat input were expected to enhance the fatigue propagation resistance. The morphology of the martensites in fusion zone was smaller compared to C-GTAW process, and a larger distribution density of basketweave structure was also obtained by UHFP-GTAW. Furthermore, the decreased fatigue crack rate was accompanied as the increased grain boundaries produced by the reduced grain size in fusion zone. Observation of fatigue fractographs revealed that the UHFP-GTAW has obvious slip traces at fatigue initiation sites and more deep secondary cracks in the crack propagation regions associated with the smaller dimples of final fracture zones. The proportion of propagation regions was much larger than C-GTAW. As a result, it can be considered as the representation of the improvement in ductility.

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