Welding and joining of components processed by additive manufacturing (AM) to other AMas well as conventionally produced components is of high importance for industry as thisallows to combine advantages of either technique and to produce large-scale structures,respectively. One of the key influencing factors with respect to weldability and mechanicalproperties of AM components was found to be the inherent microstructural anisotropy ofthese components. In present work, the precipitation-hardenable AleSi10Mg was fabri-cated in different build orientations using selective laser melting (SLM) and subsequentlyjoined by friction stir welding (FSW) in different combinations. Microstructural analysisshowed considerable grain refinement in the friction stir zone, however, pronouncedsoftening occurred in this area. The latter can be mainly attributed to changes in themorphology and size of Si particles. Upon combination of different build orientations aremarkable influence on the tensile strength of FSW joints was seen. Cyclic deformationresponses of SLM and FSW samples were examined in depth. Fatigue properties of thisalloy in the low-cycle fatigue (LCF) regime imply that SLM samples with the building di-rection parallel to the loading direction show superior performance under cyclic loading ascompared to the other conditions and the FSW joints. From results presented solid process-microstructure-property relationships are drawn.

Abstract Laser-based powder bed fusion of metals (PBF-LB/M) is found to be a promising processing method for the fabrication of components with no limits of complexity by adding layers upon layers of material. However, drawbacks such as pro- ductivity and dimension limitations adversely affect the employment of com- ponents processed by additive manufacturing (AM) in envisaged applications. This brings welding and joining techniques into play to integrate AM metal parts into larger assemblies. In the present study, electron beam welding is used to join the AlSi10Mg specimens, fabricated via two different manufacturing processes, that is, PBF-LB/M and casting. The main focus is to study the quasistatic and fatigue behavior of similar and dissimilar welded joints in different combinations, namely AM–AM, AM–cast, and cast–cast, alongside thorough microstructure analysis, to investigate the correlation between the microscopic and macroscopic properties. Dissimilar welded joints demonstrate inferior material strength. This fact can be attributed to the inherent coarse microstructure of the cast material. Although similar welded joints of AM components suffer from high porosity in the weld zone, they are characterized by a better fatigue life, which can be attributed to the equiaxed eutectic microstructure in the welded area.