Modeling of the Heat-Affected and Thermomechanically Affected Zones in a Ti-6Al-4V Inertia Friction Weld
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FRICTION welding techniques are becoming a more widespread and popular processing route for fabrication of complex components across a number of industries, notably aerospace,[1] automotive,[2] transportation,[3] and power generation. This is largely due to the concomitant benefits of microstructural refinement and controlled residual stresses[4] achieved due to the thermal, mechanical, and microstructural evolutions at the interface region of the two faying surfaces during a friction weld, compared with a more traditional fusion welding technique. One of the key features of a typical friction-welded processing route is that the interface material is generally not raised above the solidus temperature. Thus, the process is often referred to as a solid-state joining method.[5]
R.P. TURNER, B. PERUMAL, Y. LU, R.M. WARD, H.C. BASOALTO, and J.W. BROOKS are with the PRISM2 Research Group, School of Metallurgy & Materials, University of Birmingham, Birmingham, B15 2TT, UK. Contact e-mail: [email protected] Manuscript submitted June 22, 2018.
METALLURGICAL AND MATERIALS TRANSACTIONS B
Although the issue of material melting in inertia friction welding (or just inertia welding) is a controversial one, it is widely understood that across some friction welding applications using certain materials, it is possible to observe some small-scale material melting in localized regions and hot-spots.[5] The prevalence for this highly localized melting is exacerbated by a poor selection of process parameters, leading to an overly energetic friction welding process for the material selected. In addition, for some materials used in friction welding processes, interfacial melting can be observed[6] for even a successful welding parameter set. However, one of the major reasons for friction welding being used as a processing route is due to the fact that the interface material is not heated significantly above the solidus, thus avoiding the production of bulk liquid phase within the sample, and thus reducing problems associated with liquation or solidification cracking. Controlling the microstructural evolution of the interface material[7,8] for a range of ‘friction-weldable’ materials is of considerable importance to component manufacturers, as it is precisely the formed microstructure that dominates the properties of the joint. A method to target a specific microstructural evolution at specific regions of the material, such as the interface, allows for location-specific-property design, which can aid the component significantly in terms of
life-prediction and strength. In addition, the significant variation in microstructure from parent material to the interface material will modify the residual stress across the component weld interface.[8] Thus, an understanding of how the interface region microstructure has changed, moving away from its original parent condition, is advantageous. The presence of the heat-affected zone (HAZ) and the thermomechanically affected zone (TMAZ) across the weld interface within an inertia friction-welded join
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