Abstract
Abstract The cracking behaviors (i.e. crack morphologies, crack initiation and crack propagations) of titanium (TC4) and aluminum (6061 and 2024) dissimilar alloys welded joints were investigated. The results indicated that the crack initiated in the fusion zone and propagated along the grain boundaries in the fusion zone for the TC4/6061 joint, while the crack formed in the interface and serrated crack propagated in the fusion zone and interface for the TC4/2024 joint. The crack initiation and propagation in the dissimilar joints were indicated based on the thermal cycles and crack characteristics. Owing to the high cracking susceptibility of 6061 aluminum alloy, the crack formed in the fusion zone in the TC4/6061 joint, and the crack occurred in the interface and fusion zone in the TC4/2024 joint on account of the formation of brittle intermetallic compounds. Based on the analysis, the crack formation mechanism for Ti/Al dissimilar joints was clarified and possible approaches were given to avoid the crack formation.
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