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
Ni-based superalloys are one of the most important materials employed in high-temperature applications within the aerospace and nuclear energy industries and in gas turbines due to their excellent corrosion,radiation,...Ni-based superalloys are one of the most important materials employed in high-temperature applications within the aerospace and nuclear energy industries and in gas turbines due to their excellent corrosion,radiation,fatigue resistance,and high-temperature strength.Linear friction welding(LFW)is a new joining technology with near-net-forming characteristics that can be used for the manu-facture and repair of a wide range of aerospace components.This paper reviews published works on LFW of Ni-based superalloys with the aim of understanding the characteristics of frictional heat generation and extrusion deformation,microstructures,mechanical proper-ties,flash morphology,residual stresses,creep,and fatigue of Ni-based superalloy weldments produced with LFW to enable future optim-um utilization of the LFW process.展开更多
Linear Friction Welding(LFW)technology was used to realize the welding of GH4169 superalloy,and the effect of welding parameters on the microstructure,mechanical properties and corrosion behavior of the joint was anal...Linear Friction Welding(LFW)technology was used to realize the welding of GH4169 superalloy,and the effect of welding parameters on the microstructure,mechanical properties and corrosion behavior of the joint was analyzed.The results show that there is a positive correlation between the weld hardness and the tensile strength.With the gradual increase of heat input and welding pressure,the joint quality is gradually improved,but the heat affected zone is not significantly increased.The smaller the grain size of the weld,the higher the strength and plasticity of the joint.With the increase of the joint shortening amount,the corrosion resistance of the weld first gradually increases.However,when the shortening reaches a certain level,the corrosion resistance of the joint becomes little changed.With the increase of solution temperature,the corrosion current density increases and the polarization impedance decreases.The higher the corrosion temperature,the worse the corrosion resistance of the joint.There is no significant correlation between the joint strength and the corrosion resistance.The corrosion resistance of the joint can be enhanced without changing the joint mechanical properties by reducing the welding frequency and amplitude or increasing the welding pressure.展开更多
Mechanical properties of TC17 titanium alloy undergo a significant reduction after linear friction welding(LFW),of which the strength and ductility are hard to be improved simultaneously by traditional aging heat trea...Mechanical properties of TC17 titanium alloy undergo a significant reduction after linear friction welding(LFW),of which the strength and ductility are hard to be improved simultaneously by traditional aging heat treatment(AHT),seriously limiting the application of LFW in the manufacturing of TC17 titanium alloy blisks.To this end,the present work proposes to use electric pulse treatment(EPT)to enhance the strength and ductility of TC17 LFW joints simultaneously by improving its microstructure.The results show that,in comparison to the uneven distribution ofαphases in the welding zone(WZ),heat-affected zone(HAZ),and base metal(BM)zone after AHT,EPT can selectively homogenize theαphase distribution of WZ and HAZ without impacting the BM.The selective effect of EPT is reflected as the synergistic influence of the local Joule heating effect and the electron wind effect,which promotes the diffusion ofβphase stabilizing element Mo and leads to a competitive precipitation ofβphase andαphase in theαphase transition temperature range.The ratio ofαphase toβphase in the WZ and HAZ finally approaches an equilibrium point which is similar to that of BM,leading to a uniform distribution ofαphase and realizing the synergy of strength-ductility of LFW joint:the maximum strength increase observed is 12.9%,accompanied by a corresponding elongation increase of 122%(by AHT&EPT),and the maximum plasticity improvement is 185%,accompanied by a corresponding strength increase of 4.3%(by EPT for 1 h).This study provides essential insights for improving the strength and ductility of LFW TC17 titanium alloy blisks and enhancing the applications of LFW in aeroengine components.展开更多
An innovative physical simulation apparatus, including high speed camera, red thermal imaging system, and mechanical quantity sensor, was used to investigate the friction heat generation and atom diffusion behavior du...An innovative physical simulation apparatus, including high speed camera, red thermal imaging system, and mechanical quantity sensor, was used to investigate the friction heat generation and atom diffusion behavior during Mg-Ti friction welding process. The results show that the friction coefficient mainly experiences two steady stages. The first steady stage corresponds to the Coulomb friction with material abrasion. The second steady stage corresponds to the stick friction with fully plastic flow. Moreover, the increasing rates of axial displacement, temperature and friction coefficient are obviously enhanced with the increase of rotation speed and axial pressure. It can also be found that the there exists rapid diffusion phenomenon in the Mg-Ti friction welding system. The large deformation activated diffusion coefficient is about 105 higher than that activated by thermal.展开更多
The internal residual stress within a TC 17 titanium alloy joint welded by linear friction welding （LFW） was measured by the contour method, which is a relatively new and destructive technique to obtain a full map o...The internal residual stress within a TC 17 titanium alloy joint welded by linear friction welding （LFW） was measured by the contour method, which is a relatively new and destructive technique to obtain a full map of internal residual stress. The specimen was first cut into two parts; the out-of-plane displacement contour formed by the release of the residual stress was then measured; finally, taking the measured contour of the cut plane as the boundary conditions, a linear elastic finite element analysis was carried out to calculate the corresponding distribution of residual stress normal to the cut plane. The internal stress distribution of the TC 17 titanium alloy LFWjoint was also analyzed. The results show that the tensile residual stress in the TC17 LFW weld is mainly present within a region about 12 mm from the weld centerline; the peak tensile residual stress occurs at the weld centerline and reaches 360 MPa （about one third of the yield strength of TC17 alloy）; within the weld zone of the TC17 LFW weld, the through-thickness stress is not uniform, and the internal stress is larger than that near the top or bottom surface.展开更多
The aim of present study is introducing a method by subdividing friction welding phases into three steps according to the temperature change during continuous drive friction welding operation. Thermal curve allowable ...The aim of present study is introducing a method by subdividing friction welding phases into three steps according to the temperature change during continuous drive friction welding operation. Thermal curve allowable subdividing of the friction welding phase's time into three distinct periods, while the microstructure evolution during friction welding goes through three different situations. The effects of three distinct periods were achieved by macro-microscopy, microhardness HV_(0.1), tensile tests and scanning electronic microscopy(SEM).The results clearly show that the microstructure during the friction phase goes through three completely different situations which mechanically influenced on microstructure, tensile strength and ductility of the welded joint.展开更多
Friction welding （FW） is a process of solid state joining which is used extensively in recent years due to its advantages such as low heat input,production efficiency,ease of manufacture and environment friendliness...Friction welding （FW） is a process of solid state joining which is used extensively in recent years due to its advantages such as low heat input,production efficiency,ease of manufacture and environment friendliness.Friction welding can be used to join different types of ferrous metals and non-ferrous metals that cannot be welded by traditional fusion welding processes.The process parameters such as friction pressure,forging force,friction time and forging time play the major roles in determining the strength of the joints.In this investigation an attempt was made to develop an empirical relationship to predict the tensile strength of friction welded AA 6082 aluminium alloy and AISI 304 austenitic stainless steels joints,incorporating above said parameters.Response surface methodology （RSM） was applied to optimizing the friction welding process parameters to attain the maximum tensile strength of the joint.展开更多
The dissimilar joining of biodegradable magnesium alloy to pure commercial titanium by rotational friction welding with rotational speeds of 1100,1200 and 1300 r/min for the production of bio-screw was investigated.Th...The dissimilar joining of biodegradable magnesium alloy to pure commercial titanium by rotational friction welding with rotational speeds of 1100,1200 and 1300 r/min for the production of bio-screw was investigated.The metallographic analysis revealed that a good joining was obtained at the Ti/Mg alloy joint.On the magnesium alloy side,various regions such as the weld center zone(WCZ),dynamic recrystallization zone(DRX),thermo-mechanically affected zone(TMAZ)and partially deformed zone(PDZ)were observed.The highest tensile and shear strengths were 173 and 103.2 MPa,respectively at a rotational speed of 1300 r/min.The Ti/Mg alloy dissimilar friction welded joint failed at the vicinity of the intermetallic zone containing Ti3Al phase.The hardness values from the base metal magnesium alloy to the joining point increased mainly due to grain refinement(8.57μm in diameter)and the presence of titanium particles,while the hardness values were constant on the titanium side.It was also found that the corrosion rate of the Ti/Mg alloy joint was higher compared with that of the Ti and Mg alloy from the immersion studies.Additionally,the sample with a rotational speed of 1300 r/min showed better biocompatibility and a cell viability of 98.12%due to better corrosion resistance.展开更多
The current research of titanium alloy on friction welding process in the field of aero-engines mainly focuses on the linear friction welding.Compared to the linear friction welding,inertial friction welding of titani...The current research of titanium alloy on friction welding process in the field of aero-engines mainly focuses on the linear friction welding.Compared to the linear friction welding,inertial friction welding of titanium alloy still has important application position in the welding of aero-engine rotating assembly.However,up to now,few reports on inertial friction welding of titanium alloy are found.In this paper,the near-alpha TA19 titanium alloy welded joint was successfully obtained by inertial friction welding(IFW)process.The microstructures and mechanical properties were investigated systematically.Results showed that the refined grains within 15‒20μm and weak texture were found in the weld zone due to dynamic recrystallization caused by high temperature and plastic deformation.The weld zone consisted of acicularα′martensite phase,αp phase and metastableβphase.Most lath-shapedαs andβphase in base metal were transformed into acicular martensiteα′phase and metastableβphase in thermo-mechanically affected zone and heat affected zone.As a result,the microhardness of welded joint gradually decreased from the weld zone to the base metal.Tensile specimens in room temperature and high temperature of 480℃ were all fractured in base metal illustrating that the inertia friction welded TA19 titanium alloy joint owned higher tensile strength compared to the base metal.展开更多
The inertia friction welding process is a non-linear process because of the interaction between the temperature field and the material properties as well as the friction force. A thermo-mechanical coupled finite eleme...The inertia friction welding process is a non-linear process because of the interaction between the temperature field and the material properties as well as the friction force. A thermo-mechanical coupled finite element model is established to simulate the temperature field of this process. The transient temperature distribution during the inertia friction welding process of two similar workpieces of GH4169 alloy is calculated. The region of the circular cross-section of the workpiece is divided into a number of four-nodded isoparametric elements. In this model, the temperature dependent thermal properties, time dependent heat inputs, contact condition of welding interface, and deformation of the flash were considered. At the same time, the convection and radiation heat losses at the surface of the workpieces were also considered. A temperature data acquisition system was developed. The temperature at some position near the welding interface was measured using this system. The calculated temperature agrees well with the experimental data. The deformation of the flash and the factor affecting the temperature distribution at the welding interface are also discussed.展开更多
The continuous growth in the manufacture of aerospace components such as blisks has led to an increase in the application of different hybrid materials fabricating methods,and thus the requirements for joining and str...The continuous growth in the manufacture of aerospace components such as blisks has led to an increase in the application of different hybrid materials fabricating methods,and thus the requirements for joining and strengthening of dissimilar welds.According to this goal,selective laser melted(SLM)Inconel718 was joined with forged AD730^(TM)Nickel-based superalloy through linear friction welding(LFW)in this study.Microstructure variation,specifically with respect to secondary phases precipitation was investigated.The microhardness and strengthening mechanisms of the weldment were also studied.The precipitation(volume fraction and size of particles)at different regions of both sides of the weld line was characterized.Close to the weld line,the dissolution ofγ’/γ"and Laves phases and grain refinement occurred which reveals the effects of both compression strain and high temperature on recrystallization and high degree of elemental diffusion in the weld zone(WZ).It is shown that the size,volume fraction,and shape of secondary phases increased and changed(from spherical to long-striped for Laves particles)as we went from the WZ toward the base metal.However,the measured microhardness indicated that the strength of AD730^(TM)alloy depends significantly on the grain size,while strength in SLM Inconel 718 was dominated by shape(or size)and the presence of secondary phases(γ’/γ"and Laves).展开更多
Ti-6Al-4V rods were butt-welded by rotary friction welding in this study. Additionally, the radial differences in microstructure and mechanical property of joints were investigated by hierarchy slicing method. The res...Ti-6Al-4V rods were butt-welded by rotary friction welding in this study. Additionally, the radial differences in microstructure and mechanical property of joints were investigated by hierarchy slicing method. The results displayed that the width of weld zone and heat-affected zone of joints became wider along radial direction. Meanwhile, the tensile strength of joints decreased gradually along the radial direction. According to the theoretical analysis, the temperature gradient and inhomogeneous forging pressure leaded to the radial differences. Through K-type thermocouples, the actual temperatures at different locations were measured, and the results were consistent with the theoretical analysis. Theoretically, the radial differences of rotary friction welding joint are an inherent phenomenon; thus, the size of weldment should be limited strictly below the corresponding critical size. In order to prevent radial differences from enlarging, the welding surface profile of weldment can be processed into oval shape, and a larger forging pressure can be used within the scope of the joint deformation allowed according to causes for radial differences.展开更多
Friction weIding is a solid state joining process used extensively currently owing to its advantages such as low heat input, high production efficiency, ease of manufacture, and environment friendliness. Materials dif...Friction weIding is a solid state joining process used extensively currently owing to its advantages such as low heat input, high production efficiency, ease of manufacture, and environment friendliness. Materials difficult to be welded by fusion welding processes can be successfully welded by friction welding. An attempt was made to develop an empirical relationship to predict the tensile strength of friction welded AISI 1040 grade medium carbon steel and AISI 304 austenitic stainless steel, incorporating the process parameters such as friction pressure, forging pressure, friction time and forging time, which have great influence on strength of the joints. Response surface methodology was applied to optimize the friction welding process parameters to attain maximum tensile strength of the joint. The maximum tensile strength of 543 MPa could be obtained for the joints fabricated under the welding conditions of friction pressure of 90 MPa, forging pressure of 90 MPa, friction time of 6 s and forging time of 6 s.展开更多
Ti-6Al-4V alloy(Ti64)and SUS316 L stainless steel rods were dissimilarly friction welded.Especially focusing on the detailed observation of interface microstructural evolution during the friction welding(FW),the relat...Ti-6Al-4V alloy(Ti64)and SUS316 L stainless steel rods were dissimilarly friction welded.Especially focusing on the detailed observation of interface microstructural evolution during the friction welding(FW),the relationship between the processing conditions,weld interface microstructure,and mechanical properties of the obtained joints were systematically investigated to elucidate the principle for obtaining a high joint quality in the FW of Ti64 and SUS316L.A higher friction pressure produced a lower welding temperature in the FW,hence suppressing the thick intermetallic compound layer formation.However,hard and brittle Ti64/SUS316L mechanically mixed layers generally formed especially at the weld interface periphery due to the high temperature increasing rate,high rotation linear velocity and high outward flow velocity of the Ti64.These harmful layers tended to induce the cracks/voids formation at the weld interfaces hence deteriorating the joints’mechanical properties.The rotation speed reduction and liquid CO2 cooling during the entire processing decreased the temperature increasing rate,rotation linear velocity and outward flow velocity of the Ti64 at the weld interface periphery.Therefore,they suppressed the formation of the harmful mechanically mixed layers,facilitated the homogeneous and sound interface microstructure generation,and finally produced a high-quality dissimilar joint in the FW of Ti64 and SUS316L.展开更多
A method to decide near optimal settings of the process parameters in friction welding was proposed.The success of the friction welding process is based on various input parameters like friction pressure,friction time...A method to decide near optimal settings of the process parameters in friction welding was proposed.The success of the friction welding process is based on various input parameters like friction pressure,friction time,upset pressure and upset time and output parameters like tensile strength,hardness and material loss.Ti-6Al-4V and SS304L(SS) materials were joined by friction welding process using interlayer techniques.The Box-Behnken design and response surface methodology(RSM) were applied to deciding the number of experiments to be performed and identify the optimum process parameters for obtaining better joint strength.The results were highly encouraging.Join strength of 523 MPa was obtained at a friction pressure of 12 N/mm^2,upset pressure of40 N/mm^2,friction time of 1.2 s and upset time of 7 s.展开更多
The optimum friction welding （FW） parameters of duplex stainless steel （DSS） UNS $32205 joint was determined. The experiment was carried out as the central composite array of 30 experiments. The selected input par...The optimum friction welding （FW） parameters of duplex stainless steel （DSS） UNS $32205 joint was determined. The experiment was carried out as the central composite array of 30 experiments. The selected input parameters were friction pressure （F）, upset pressure （U）, speed （S） and burn-off length （B）, and responses were hardness and ultimate tensile strength. To achieve the quality of the welded joint, the ultimate tensile strength and hardness were maximized, and response surface methodology （RSM） was applied to create separate regression equations of tensile strength and hardness. Intelligent optimization technique such as genetic algorithm was used to predict the Pareto optimal solutions. Depending upon the application, preferred suitable welding parameters were selected. It was inferred that the changing hardness and tensile strength of the friction welded joint influenced the upset pressure, friction Pressure and speed of rotation.展开更多
Micro-pore is a very common material defect. In the present paper, the temperature fields of medium carbon steel joints with and without micro-pore defect during linear friction welding （LFW） were investigated by us...Micro-pore is a very common material defect. In the present paper, the temperature fields of medium carbon steel joints with and without micro-pore defect during linear friction welding （LFW） were investigated by using finite element method. The effect of micro-pore defect on the axial shortening of joints during LFW was examined. The x- and y-direction displacements of micro-pore during the LFW process were also studied. In addition, the shape of micro-pore after LFW was observed. The heat conducted from the weld inteace to the specimen interior. The fluctuation range of the temperature curves for the joint with micro-pore is larger than that without micro-pore. Position of micro-pore changes with the change of the friction time. The circular shape of micro-pore becomes oval after welding.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supported by the National Natural Science Foundation of China(Nos.52074228,52305420,and 51875470)the China Postdoctoral Science Foundation(No.2023M742830)the Xi’an Beilin District Science and Technology Planning Project,China(No.GX2349).
文摘Ni-based superalloys are one of the most important materials employed in high-temperature applications within the aerospace and nuclear energy industries and in gas turbines due to their excellent corrosion,radiation,fatigue resistance,and high-temperature strength.Linear friction welding(LFW)is a new joining technology with near-net-forming characteristics that can be used for the manu-facture and repair of a wide range of aerospace components.This paper reviews published works on LFW of Ni-based superalloys with the aim of understanding the characteristics of frictional heat generation and extrusion deformation,microstructures,mechanical proper-ties,flash morphology,residual stresses,creep,and fatigue of Ni-based superalloy weldments produced with LFW to enable future optim-um utilization of the LFW process.
基金supported by the research fund of the National Natural Science Foundation of China(Nos.52305420,52074228,51875470)the China Postdoctoral Science Foundation(No.2023M742830)the Xi’an Beilin District Science and Technology Planning Project,China(No.GX2349).
文摘Linear Friction Welding(LFW)technology was used to realize the welding of GH4169 superalloy,and the effect of welding parameters on the microstructure,mechanical properties and corrosion behavior of the joint was analyzed.The results show that there is a positive correlation between the weld hardness and the tensile strength.With the gradual increase of heat input and welding pressure,the joint quality is gradually improved,but the heat affected zone is not significantly increased.The smaller the grain size of the weld,the higher the strength and plasticity of the joint.With the increase of the joint shortening amount,the corrosion resistance of the weld first gradually increases.However,when the shortening reaches a certain level,the corrosion resistance of the joint becomes little changed.With the increase of solution temperature,the corrosion current density increases and the polarization impedance decreases.The higher the corrosion temperature,the worse the corrosion resistance of the joint.There is no significant correlation between the joint strength and the corrosion resistance.The corrosion resistance of the joint can be enhanced without changing the joint mechanical properties by reducing the welding frequency and amplitude or increasing the welding pressure.
基金the National Science Fund for Distinguished Young Scholars(No.52225505)the National Sci-ence and Technology Major Project(No.J2019-VII-0014-0154)+1 种基金the National Natural Science Foundation of China(No.52005412)the Open Research Fund of State Key Laboratory of Precision Man-ufacturing for Extreme Service Performance(No.Kfkt2023-12)for financial supports given to this research.
文摘Mechanical properties of TC17 titanium alloy undergo a significant reduction after linear friction welding(LFW),of which the strength and ductility are hard to be improved simultaneously by traditional aging heat treatment(AHT),seriously limiting the application of LFW in the manufacturing of TC17 titanium alloy blisks.To this end,the present work proposes to use electric pulse treatment(EPT)to enhance the strength and ductility of TC17 LFW joints simultaneously by improving its microstructure.The results show that,in comparison to the uneven distribution ofαphases in the welding zone(WZ),heat-affected zone(HAZ),and base metal(BM)zone after AHT,EPT can selectively homogenize theαphase distribution of WZ and HAZ without impacting the BM.The selective effect of EPT is reflected as the synergistic influence of the local Joule heating effect and the electron wind effect,which promotes the diffusion ofβphase stabilizing element Mo and leads to a competitive precipitation ofβphase andαphase in theαphase transition temperature range.The ratio ofαphase toβphase in the WZ and HAZ finally approaches an equilibrium point which is similar to that of BM,leading to a uniform distribution ofαphase and realizing the synergy of strength-ductility of LFW joint:the maximum strength increase observed is 12.9%,accompanied by a corresponding elongation increase of 122%(by AHT&EPT),and the maximum plasticity improvement is 185%,accompanied by a corresponding strength increase of 4.3%(by EPT for 1 h).This study provides essential insights for improving the strength and ductility of LFW TC17 titanium alloy blisks and enhancing the applications of LFW in aeroengine components.
基金Projects (51101126, 51071123) supported by the National Natural Science Foundation of ChinaProjects (20110491684, 2012T50817) supported by the China Postdoctoral Science FoundationProject (20110942K) supported by the Open Fund of State Key Laboratory of Powder Metallurgy of Central South University, China
文摘An innovative physical simulation apparatus, including high speed camera, red thermal imaging system, and mechanical quantity sensor, was used to investigate the friction heat generation and atom diffusion behavior during Mg-Ti friction welding process. The results show that the friction coefficient mainly experiences two steady stages. The first steady stage corresponds to the Coulomb friction with material abrasion. The second steady stage corresponds to the stick friction with fully plastic flow. Moreover, the increasing rates of axial displacement, temperature and friction coefficient are obviously enhanced with the increase of rotation speed and axial pressure. It can also be found that the there exists rapid diffusion phenomenon in the Mg-Ti friction welding system. The large deformation activated diffusion coefficient is about 105 higher than that activated by thermal.
基金Project(35061107)supported by the Doctoral Initiation Project of Jiangsu University of Science and Technology,China
文摘The internal residual stress within a TC 17 titanium alloy joint welded by linear friction welding （LFW） was measured by the contour method, which is a relatively new and destructive technique to obtain a full map of internal residual stress. The specimen was first cut into two parts; the out-of-plane displacement contour formed by the release of the residual stress was then measured; finally, taking the measured contour of the cut plane as the boundary conditions, a linear elastic finite element analysis was carried out to calculate the corresponding distribution of residual stress normal to the cut plane. The internal stress distribution of the TC 17 titanium alloy LFWjoint was also analyzed. The results show that the tensile residual stress in the TC17 LFW weld is mainly present within a region about 12 mm from the weld centerline; the peak tensile residual stress occurs at the weld centerline and reaches 360 MPa （about one third of the yield strength of TC17 alloy）; within the weld zone of the TC17 LFW weld, the through-thickness stress is not uniform, and the internal stress is larger than that near the top or bottom surface.
文摘The aim of present study is introducing a method by subdividing friction welding phases into three steps according to the temperature change during continuous drive friction welding operation. Thermal curve allowable subdividing of the friction welding phase's time into three distinct periods, while the microstructure evolution during friction welding goes through three different situations. The effects of three distinct periods were achieved by macro-microscopy, microhardness HV_(0.1), tensile tests and scanning electronic microscopy(SEM).The results clearly show that the microstructure during the friction phase goes through three completely different situations which mechanically influenced on microstructure, tensile strength and ductility of the welded joint.
文摘Friction welding （FW） is a process of solid state joining which is used extensively in recent years due to its advantages such as low heat input,production efficiency,ease of manufacture and environment friendliness.Friction welding can be used to join different types of ferrous metals and non-ferrous metals that cannot be welded by traditional fusion welding processes.The process parameters such as friction pressure,forging force,friction time and forging time play the major roles in determining the strength of the joints.In this investigation an attempt was made to develop an empirical relationship to predict the tensile strength of friction welded AA 6082 aluminium alloy and AISI 304 austenitic stainless steels joints,incorporating above said parameters.Response surface methodology （RSM） was applied to optimizing the friction welding process parameters to attain the maximum tensile strength of the joint.
文摘The dissimilar joining of biodegradable magnesium alloy to pure commercial titanium by rotational friction welding with rotational speeds of 1100,1200 and 1300 r/min for the production of bio-screw was investigated.The metallographic analysis revealed that a good joining was obtained at the Ti/Mg alloy joint.On the magnesium alloy side,various regions such as the weld center zone(WCZ),dynamic recrystallization zone(DRX),thermo-mechanically affected zone(TMAZ)and partially deformed zone(PDZ)were observed.The highest tensile and shear strengths were 173 and 103.2 MPa,respectively at a rotational speed of 1300 r/min.The Ti/Mg alloy dissimilar friction welded joint failed at the vicinity of the intermetallic zone containing Ti3Al phase.The hardness values from the base metal magnesium alloy to the joining point increased mainly due to grain refinement(8.57μm in diameter)and the presence of titanium particles,while the hardness values were constant on the titanium side.It was also found that the corrosion rate of the Ti/Mg alloy joint was higher compared with that of the Ti and Mg alloy from the immersion studies.Additionally,the sample with a rotational speed of 1300 r/min showed better biocompatibility and a cell viability of 98.12%due to better corrosion resistance.
基金Supported by Natural Science Foundation to Basic Research in Key Areas of Heilongjiang Province of China(Grant No.TD2020E002).
文摘The current research of titanium alloy on friction welding process in the field of aero-engines mainly focuses on the linear friction welding.Compared to the linear friction welding,inertial friction welding of titanium alloy still has important application position in the welding of aero-engine rotating assembly.However,up to now,few reports on inertial friction welding of titanium alloy are found.In this paper,the near-alpha TA19 titanium alloy welded joint was successfully obtained by inertial friction welding(IFW)process.The microstructures and mechanical properties were investigated systematically.Results showed that the refined grains within 15‒20μm and weak texture were found in the weld zone due to dynamic recrystallization caused by high temperature and plastic deformation.The weld zone consisted of acicularα′martensite phase,αp phase and metastableβphase.Most lath-shapedαs andβphase in base metal were transformed into acicular martensiteα′phase and metastableβphase in thermo-mechanically affected zone and heat affected zone.As a result,the microhardness of welded joint gradually decreased from the weld zone to the base metal.Tensile specimens in room temperature and high temperature of 480℃ were all fractured in base metal illustrating that the inertia friction welded TA19 titanium alloy joint owned higher tensile strength compared to the base metal.
文摘The inertia friction welding process is a non-linear process because of the interaction between the temperature field and the material properties as well as the friction force. A thermo-mechanical coupled finite element model is established to simulate the temperature field of this process. The transient temperature distribution during the inertia friction welding process of two similar workpieces of GH4169 alloy is calculated. The region of the circular cross-section of the workpiece is divided into a number of four-nodded isoparametric elements. In this model, the temperature dependent thermal properties, time dependent heat inputs, contact condition of welding interface, and deformation of the flash were considered. At the same time, the convection and radiation heat losses at the surface of the workpieces were also considered. A temperature data acquisition system was developed. The temperature at some position near the welding interface was measured using this system. The calculated temperature agrees well with the experimental data. The deformation of the flash and the factor affecting the temperature distribution at the welding interface are also discussed.
基金The authors gratefully acknowledge the support from the Natural Sciences and Engineering Research Council of Canada(NSERC)2018–03889 through a Discovery Grant.Thanks to Mr.Adrien Lieurey(IMT-Mines Albi ICA-site Albi)for his involvement and fabrication of SLM parts.They would also like to express their gratitude to Aubert&Duval Co.,Dr.Alexandre Devaux,and Prof.Cormier for providing forged AD730™samples and discussions on the definition of the scope of the project.Special thanks to TWI Ltd.for carrying out the LFW of the samples.
文摘The continuous growth in the manufacture of aerospace components such as blisks has led to an increase in the application of different hybrid materials fabricating methods,and thus the requirements for joining and strengthening of dissimilar welds.According to this goal,selective laser melted(SLM)Inconel718 was joined with forged AD730^(TM)Nickel-based superalloy through linear friction welding(LFW)in this study.Microstructure variation,specifically with respect to secondary phases precipitation was investigated.The microhardness and strengthening mechanisms of the weldment were also studied.The precipitation(volume fraction and size of particles)at different regions of both sides of the weld line was characterized.Close to the weld line,the dissolution ofγ’/γ"and Laves phases and grain refinement occurred which reveals the effects of both compression strain and high temperature on recrystallization and high degree of elemental diffusion in the weld zone(WZ).It is shown that the size,volume fraction,and shape of secondary phases increased and changed(from spherical to long-striped for Laves particles)as we went from the WZ toward the base metal.However,the measured microhardness indicated that the strength of AD730^(TM)alloy depends significantly on the grain size,while strength in SLM Inconel 718 was dominated by shape(or size)and the presence of secondary phases(γ’/γ"and Laves).
基金financially supported by the National Natural Science Foundation of China(No.51405390)Project of Key areas of innovation team in Shaanxi Province(No.2014KCT-12)+3 种基金Northwestern Polytechnical University Foundation for Fundamental Research(No.3102014JCQ01017)the fund of the State Key Laboratory of Solidification Processing in NWPU(No.113-QP-2014)Natural Science Foundation of Shaanxi Province(No.2014JM2-5083)the Program of Introducing Talents of Discipline to Universities(No.B08040)
文摘Ti-6Al-4V rods were butt-welded by rotary friction welding in this study. Additionally, the radial differences in microstructure and mechanical property of joints were investigated by hierarchy slicing method. The results displayed that the width of weld zone and heat-affected zone of joints became wider along radial direction. Meanwhile, the tensile strength of joints decreased gradually along the radial direction. According to the theoretical analysis, the temperature gradient and inhomogeneous forging pressure leaded to the radial differences. Through K-type thermocouples, the actual temperatures at different locations were measured, and the results were consistent with the theoretical analysis. Theoretically, the radial differences of rotary friction welding joint are an inherent phenomenon; thus, the size of weldment should be limited strictly below the corresponding critical size. In order to prevent radial differences from enlarging, the welding surface profile of weldment can be processed into oval shape, and a larger forging pressure can be used within the scope of the joint deformation allowed according to causes for radial differences.
文摘Friction weIding is a solid state joining process used extensively currently owing to its advantages such as low heat input, high production efficiency, ease of manufacture, and environment friendliness. Materials difficult to be welded by fusion welding processes can be successfully welded by friction welding. An attempt was made to develop an empirical relationship to predict the tensile strength of friction welded AISI 1040 grade medium carbon steel and AISI 304 austenitic stainless steel, incorporating the process parameters such as friction pressure, forging pressure, friction time and forging time, which have great influence on strength of the joints. Response surface methodology was applied to optimize the friction welding process parameters to attain maximum tensile strength of the joint. The maximum tensile strength of 543 MPa could be obtained for the joints fabricated under the welding conditions of friction pressure of 90 MPa, forging pressure of 90 MPa, friction time of 6 s and forging time of 6 s.
基金the New Energy and Industrial Technology Development Organization(NEDO)under the“Innovation Structural Materials Project(Future Pioneering Projects)”JSPS KAKENHI Grant Numbers JP19H00826 and JP18K14027an ISIJ Research Promotion Grant。
文摘Ti-6Al-4V alloy(Ti64)and SUS316 L stainless steel rods were dissimilarly friction welded.Especially focusing on the detailed observation of interface microstructural evolution during the friction welding(FW),the relationship between the processing conditions,weld interface microstructure,and mechanical properties of the obtained joints were systematically investigated to elucidate the principle for obtaining a high joint quality in the FW of Ti64 and SUS316L.A higher friction pressure produced a lower welding temperature in the FW,hence suppressing the thick intermetallic compound layer formation.However,hard and brittle Ti64/SUS316L mechanically mixed layers generally formed especially at the weld interface periphery due to the high temperature increasing rate,high rotation linear velocity and high outward flow velocity of the Ti64.These harmful layers tended to induce the cracks/voids formation at the weld interfaces hence deteriorating the joints’mechanical properties.The rotation speed reduction and liquid CO2 cooling during the entire processing decreased the temperature increasing rate,rotation linear velocity and outward flow velocity of the Ti64 at the weld interface periphery.Therefore,they suppressed the formation of the harmful mechanically mixed layers,facilitated the homogeneous and sound interface microstructure generation,and finally produced a high-quality dissimilar joint in the FW of Ti64 and SUS316L.
文摘A method to decide near optimal settings of the process parameters in friction welding was proposed.The success of the friction welding process is based on various input parameters like friction pressure,friction time,upset pressure and upset time and output parameters like tensile strength,hardness and material loss.Ti-6Al-4V and SS304L(SS) materials were joined by friction welding process using interlayer techniques.The Box-Behnken design and response surface methodology(RSM) were applied to deciding the number of experiments to be performed and identify the optimum process parameters for obtaining better joint strength.The results were highly encouraging.Join strength of 523 MPa was obtained at a friction pressure of 12 N/mm^2,upset pressure of40 N/mm^2,friction time of 1.2 s and upset time of 7 s.
文摘The optimum friction welding （FW） parameters of duplex stainless steel （DSS） UNS $32205 joint was determined. The experiment was carried out as the central composite array of 30 experiments. The selected input parameters were friction pressure （F）, upset pressure （U）, speed （S） and burn-off length （B）, and responses were hardness and ultimate tensile strength. To achieve the quality of the welded joint, the ultimate tensile strength and hardness were maximized, and response surface methodology （RSM） was applied to create separate regression equations of tensile strength and hardness. Intelligent optimization technique such as genetic algorithm was used to predict the Pareto optimal solutions. Depending upon the application, preferred suitable welding parameters were selected. It was inferred that the changing hardness and tensile strength of the friction welded joint influenced the upset pressure, friction Pressure and speed of rotation.
基金The authors would like to appreeiate the National Natural Science Foundation of China （51005180）, the Fok Ying-Tong Educalion Fuundalion for Young Teachers in the Higher Education Institutions of China （131052） , the Fundamental Research Fund of NPU（JC201233） , and the 111 Project of China （B08040）.
文摘Micro-pore is a very common material defect. In the present paper, the temperature fields of medium carbon steel joints with and without micro-pore defect during linear friction welding （LFW） were investigated by using finite element method. The effect of micro-pore defect on the axial shortening of joints during LFW was examined. The x- and y-direction displacements of micro-pore during the LFW process were also studied. In addition, the shape of micro-pore after LFW was observed. The heat conducted from the weld inteace to the specimen interior. The fluctuation range of the temperature curves for the joint with micro-pore is larger than that without micro-pore. Position of micro-pore changes with the change of the friction time. The circular shape of micro-pore becomes oval after welding.
