GH4169 joints manufactured by Linear Friction Welding(LFW)are subjected to tensile test and stair-case method to evaluate the High Cycle Fatigue(HCF)performance at 650℃.The yield and ultimate tensile strengths are 58...GH4169 joints manufactured by Linear Friction Welding(LFW)are subjected to tensile test and stair-case method to evaluate the High Cycle Fatigue(HCF)performance at 650℃.The yield and ultimate tensile strengths are 582 MPa and 820 MPa,respectively.The HCF strength of joint reaches 400 MPa,which is slightly lower than that of Base Metal(BM),indicating reliable quality of this type of joint.The microstructure observation results show that all cracks initiate at the inside of specimens and transfer into deeper region with decrease of external stress,and the crack initiation site is related with microhardness of matrix.The Electron Backscattered Diffraction(EBSD)results of the observed regions with different distances to fracture show that plastic deformation plays a key role in HCF,and the Schmid factor of most grains near fracture exceeds 0.4.In addition,the generation of twins plays a vital role in strain concentration release and coordinating plastic deformation among grains.展开更多
In this study,a new linear friction welding(LFW)process,embedded LFW process,was put forward,which was mainly applied to combination manufacturing of long or overlong loadcarrying titanium alloy structural components ...In this study,a new linear friction welding(LFW)process,embedded LFW process,was put forward,which was mainly applied to combination manufacturing of long or overlong loadcarrying titanium alloy structural components in aircraft.The interfacial plastic flow behavior and bonding mechanism of this process were investigated by a developed coupling EulerianLagrangian numerical model using software ABAQUS and a novel thermo-physical simulation method with designed embedded hot compression specimen.In addition,the formation mechanism and control method of welding defects caused by uneven plastic flow were discussed.The results reveal that the plastic flow along oscillating direction of this process is even and sufficient.In the direction perpendicular to oscillation,thermo-plastic metals mainly flow downward along welding interface under coupling of shear stress and interfacial pressure,resulting in the interfacial plastic zone shown as an inverted“V”shape.The upward plastic flow in this direction is relatively weak,and only a small amount of flash is extruded from top of joint.Moreover,the wedge block and welding components at top of joint are always in un-steady friction stage,leading to nonuniform temperature field distribution and un-welded defects.According to the results of numerical simulation,high oscillating frequency combined with low pressure and small amplitude is considered as appropriate parameter selection scheme to improve the upward interfacial plastic flow at top of joint and suppress the un-welded defects.The results of thermo-physical simulation illustrate that continuous dynamic recrystallization(CDRX)induces the bonding of interface,accompanying by intense dislocation movement and creation of many low-angle grain boundaries.In the interfacial bonding area,grain orientation is random with relatively low texture density(5.0 mud)owing to CDRX.展开更多
The coupling between heat and pressure is the kernel of inertia friction welding(IFW)and is still not fully understood.A novel 3D fully coupled finite element model based on a plastic friction pair was developed to si...The coupling between heat and pressure is the kernel of inertia friction welding(IFW)and is still not fully understood.A novel 3D fully coupled finite element model based on a plastic friction pair was developed to simulate the IFW process of a Ni-based superalloy and reveal the omnidirectional thermo-mechanical coupling mechanism of the friction interface.The numerical model successfully simulated the deceleration,deformation processes,and peak torsional moments in IFW and captured the evolution of temperature,contact pressure,and stress.The simulated results were validated through measured thermal history,optical macrography,and axial shortening.The results indicated that interfacial friction heat was the primary heat source,and plastic deformation energy only accounted for 4%of the total.The increase in initial rotational speed and friction pressure elevated the peak temperature,reaching a maximum of 1525.5K at an initial rotational speed of 2000 r/min and friction pressure of 400 MPa.The interface heat generation could form an axial temperature gradient exceeding 320K/mm.The radial inhomogeneities of heat generation and temperature were manifested in a concentric ring distribution with maximum heat flux and temperature ranging from 2/5 to 2/3 radius.The radial inhomogeneities were caused by increasing linear velocity along the radius and an opposite distribution of contact pressure,which could reach 1.7 times the set pressure at the center.The circumferential inhomogeneity of thermomechanical distribution during rotary friction welding was revealed for the first time,benefiting from the 3D model.The deflection and transformation of distribution in contact pressure and Mises stress were indicators of plastic deformation and transition of quasi-steady state welding.The critical Mises stress was 0.5 times the friction pressure in this study.The presented modeling provides a reliable insight into the thermo-mechanical coupling mechanism of IFW and lays a solid foundation for predicting the microstructures and mechanical properties of inertia friction welded joints.展开更多
The performance of welded Ni-based superalloys at high temperatures is essential to be evaluated due to their particular service environment for aero-engines and high-speed aircrafts.The tensile properties and related...The performance of welded Ni-based superalloys at high temperatures is essential to be evaluated due to their particular service environment for aero-engines and high-speed aircrafts.The tensile properties and related microstructural evolutions such as the carbide precipitate and grain of a laser-welded Ni-based alloy were experimentally and numerically investigated at different temperatures(20,300,500,800℃).The results show that at room temperature,the strength of the Base Material(BM)was slightly smaller,with a difference of less than 1%,than the Welded Material(WM),which can be attributed to the more uniformly distributed needle-shaped carbide precipitates in the WM than those nonuniformly coarser spherical ones in the BM.While at 300℃ and 500℃,the strength of WM decreased more obviously compared with that of BM due to the more apparent growth of grain:13.52%loss in yield strength in WM alloys as compared with BM alloys at 300℃,and 16.57% at 500℃.At 800℃,the strength of BM and WM both decreased to a similar level due to Dynamic Recrystallization(DRX).However,a much higher elongation was observed for the BM than WM(less than 50%of BM),which can be attributed to the enhanced dislocation accumulation capability of the large spherical carbides along grain boundaries on the fracture surface in BM.Furthermore,a unified model considering the welding effects on both microstructures(dislocation,carbides,and grain)and mechanical properties evolutions at different temperatures was developed and validated.Based on this model,the key temperature ranges(20–600℃)where apparent weakening of strength and uniform plasticity occurs for welded structures were identified,providing a direct guidance for potential structure and process design.展开更多
Both experimental and simulation approaches were employed to investigate the laser ablation mechanism and performances of Glass Fiber Reinforced Phenolic Composites(GFRP).During the ablation process,the difference in ...Both experimental and simulation approaches were employed to investigate the laser ablation mechanism and performances of Glass Fiber Reinforced Phenolic Composites(GFRP).During the ablation process,the difference in thermal conductivities of the glass fibers and the resin matrix as well as their discrepant physical and chemical reactions form a conical ablation morphology.The formation of a residual carbon layer effectively mitigates the ablation rate in the thickness direction.A higher power density results in a faster ablation rate,while a longer irradiation time leads to a larger ablation pit diameter.To account for the variation in thermal conductivity between the fiber and resin,a macro-mesoscale model was developed to differentiate the matrix from the fiber components.Finite element analysis revealed that laser irradiation leads to phenolic decomposition,glass fiber melting vaporization,and residual carbon skeleton evaporation.The dual-scale model exhibits precise prediction capabilities concerning the laser ablation process of GFRP,and its accuracy is confirmed through the comparison of simulation and experimental results for the GFRP laser ablation process.This model provides a feasible method for performance evaluation and lifetime prediction of GFRP subjected to continuous wave laser irradiation.展开更多
基金supported by the National Natural Science Foundation of China(Nos.52074228,52305420,and 51875470)the China Postdoctoral Science Foundation(No.2023M742830)。
文摘GH4169 joints manufactured by Linear Friction Welding(LFW)are subjected to tensile test and stair-case method to evaluate the High Cycle Fatigue(HCF)performance at 650℃.The yield and ultimate tensile strengths are 582 MPa and 820 MPa,respectively.The HCF strength of joint reaches 400 MPa,which is slightly lower than that of Base Metal(BM),indicating reliable quality of this type of joint.The microstructure observation results show that all cracks initiate at the inside of specimens and transfer into deeper region with decrease of external stress,and the crack initiation site is related with microhardness of matrix.The Electron Backscattered Diffraction(EBSD)results of the observed regions with different distances to fracture show that plastic deformation plays a key role in HCF,and the Schmid factor of most grains near fracture exceeds 0.4.In addition,the generation of twins plays a vital role in strain concentration release and coordinating plastic deformation among grains.
基金co-supported by the National Natural Science Foundation of China(Nos.52105411,52105400and 52305420)the China Postdoctoral Science Foundation(No.2023M742830)Innovation Foundation for Doctor Dissertation of Northwestern Polytechnical University(No.CX2023008).
文摘In this study,a new linear friction welding(LFW)process,embedded LFW process,was put forward,which was mainly applied to combination manufacturing of long or overlong loadcarrying titanium alloy structural components in aircraft.The interfacial plastic flow behavior and bonding mechanism of this process were investigated by a developed coupling EulerianLagrangian numerical model using software ABAQUS and a novel thermo-physical simulation method with designed embedded hot compression specimen.In addition,the formation mechanism and control method of welding defects caused by uneven plastic flow were discussed.The results reveal that the plastic flow along oscillating direction of this process is even and sufficient.In the direction perpendicular to oscillation,thermo-plastic metals mainly flow downward along welding interface under coupling of shear stress and interfacial pressure,resulting in the interfacial plastic zone shown as an inverted“V”shape.The upward plastic flow in this direction is relatively weak,and only a small amount of flash is extruded from top of joint.Moreover,the wedge block and welding components at top of joint are always in un-steady friction stage,leading to nonuniform temperature field distribution and un-welded defects.According to the results of numerical simulation,high oscillating frequency combined with low pressure and small amplitude is considered as appropriate parameter selection scheme to improve the upward interfacial plastic flow at top of joint and suppress the un-welded defects.The results of thermo-physical simulation illustrate that continuous dynamic recrystallization(CDRX)induces the bonding of interface,accompanying by intense dislocation movement and creation of many low-angle grain boundaries.In the interfacial bonding area,grain orientation is random with relatively low texture density(5.0 mud)owing to CDRX.
基金supported by the National Key Research and Development Program of China(Grant No.2022YFB3404904)。
文摘The coupling between heat and pressure is the kernel of inertia friction welding(IFW)and is still not fully understood.A novel 3D fully coupled finite element model based on a plastic friction pair was developed to simulate the IFW process of a Ni-based superalloy and reveal the omnidirectional thermo-mechanical coupling mechanism of the friction interface.The numerical model successfully simulated the deceleration,deformation processes,and peak torsional moments in IFW and captured the evolution of temperature,contact pressure,and stress.The simulated results were validated through measured thermal history,optical macrography,and axial shortening.The results indicated that interfacial friction heat was the primary heat source,and plastic deformation energy only accounted for 4%of the total.The increase in initial rotational speed and friction pressure elevated the peak temperature,reaching a maximum of 1525.5K at an initial rotational speed of 2000 r/min and friction pressure of 400 MPa.The interface heat generation could form an axial temperature gradient exceeding 320K/mm.The radial inhomogeneities of heat generation and temperature were manifested in a concentric ring distribution with maximum heat flux and temperature ranging from 2/5 to 2/3 radius.The radial inhomogeneities were caused by increasing linear velocity along the radius and an opposite distribution of contact pressure,which could reach 1.7 times the set pressure at the center.The circumferential inhomogeneity of thermomechanical distribution during rotary friction welding was revealed for the first time,benefiting from the 3D model.The deflection and transformation of distribution in contact pressure and Mises stress were indicators of plastic deformation and transition of quasi-steady state welding.The critical Mises stress was 0.5 times the friction pressure in this study.The presented modeling provides a reliable insight into the thermo-mechanical coupling mechanism of IFW and lays a solid foundation for predicting the microstructures and mechanical properties of inertia friction welded joints.
基金co-supported by the financial support from the Fundamental Research Funds for the Central Universities,China(Nos.YWF-23-L-1012,YWF-22-L-1017)the National Natural Science Foundation of China(No.52005020)。
文摘The performance of welded Ni-based superalloys at high temperatures is essential to be evaluated due to their particular service environment for aero-engines and high-speed aircrafts.The tensile properties and related microstructural evolutions such as the carbide precipitate and grain of a laser-welded Ni-based alloy were experimentally and numerically investigated at different temperatures(20,300,500,800℃).The results show that at room temperature,the strength of the Base Material(BM)was slightly smaller,with a difference of less than 1%,than the Welded Material(WM),which can be attributed to the more uniformly distributed needle-shaped carbide precipitates in the WM than those nonuniformly coarser spherical ones in the BM.While at 300℃ and 500℃,the strength of WM decreased more obviously compared with that of BM due to the more apparent growth of grain:13.52%loss in yield strength in WM alloys as compared with BM alloys at 300℃,and 16.57% at 500℃.At 800℃,the strength of BM and WM both decreased to a similar level due to Dynamic Recrystallization(DRX).However,a much higher elongation was observed for the BM than WM(less than 50%of BM),which can be attributed to the enhanced dislocation accumulation capability of the large spherical carbides along grain boundaries on the fracture surface in BM.Furthermore,a unified model considering the welding effects on both microstructures(dislocation,carbides,and grain)and mechanical properties evolutions at different temperatures was developed and validated.Based on this model,the key temperature ranges(20–600℃)where apparent weakening of strength and uniform plasticity occurs for welded structures were identified,providing a direct guidance for potential structure and process design.
基金supported by the Fundamental Research Funds for the Central Universities,China(No.2232022D-28)the Young Elite Scientists Sponsorship Program by the China Association for Science and Technology(No.2016QNRC001).
文摘Both experimental and simulation approaches were employed to investigate the laser ablation mechanism and performances of Glass Fiber Reinforced Phenolic Composites(GFRP).During the ablation process,the difference in thermal conductivities of the glass fibers and the resin matrix as well as their discrepant physical and chemical reactions form a conical ablation morphology.The formation of a residual carbon layer effectively mitigates the ablation rate in the thickness direction.A higher power density results in a faster ablation rate,while a longer irradiation time leads to a larger ablation pit diameter.To account for the variation in thermal conductivity between the fiber and resin,a macro-mesoscale model was developed to differentiate the matrix from the fiber components.Finite element analysis revealed that laser irradiation leads to phenolic decomposition,glass fiber melting vaporization,and residual carbon skeleton evaporation.The dual-scale model exhibits precise prediction capabilities concerning the laser ablation process of GFRP,and its accuracy is confirmed through the comparison of simulation and experimental results for the GFRP laser ablation process.This model provides a feasible method for performance evaluation and lifetime prediction of GFRP subjected to continuous wave laser irradiation.
