Abstract
The linear friction welding (LFW) process is finding increasing interest from industry for the fabrication of near-net-shape, titanium alloy Ti–6Al–4V, aerospace components. Currently, the removal of surface contaminants, such as oxides and foreign particles, from the weld interface into the flash is not fully understood. To address this problem, two-dimensional (2D) computational models were developed using the finite element analysis (FEA) software DEFORM and validated with experiments. The key findings showed that the welds made with higher applied forces required less burn-off to completely remove the surface contaminants from the interface into the flash; the interface temperature increased as the applied force was decreased or the rubbing velocity increased; and the boundary temperature between the rapid flash formation and negligible material flow was approximately 970 °C. An understanding of these phenomena is of particular interest for the industrialisation of near-net-shape titanium alloy aerospace components.
Highlights
Linear friction welding (LFW) is a solid-state joining process that is used for the fabrication of near-net-shape, titanium alloyTi–6Al–4V, aerospace components [1,2]
The following conclusions can be made from this work: (1) The 2D models gave an insight into the process fundamentals for the linear friction welding (LFW) of Ti–6Al–4V workpieces
(2) The measurements from the finite element analysis and the experimental microstructural observations suggest that the weld interface exceeded the beta-transus temperature and experienced dynamic recrystallisation
Summary
Linear friction welding (LFW) is a solid-state joining process that is used for the fabrication of near-net-shape, titanium alloy. Ti–6Al–4V, aerospace components [1,2]. This is primarily due to the significant cost savings can be achieved when compared to other manufacturing techniques [2,3]. During LFW one workpiece is oscillated relative to another whilst under a compressive force. Despite being one continuous process, LFW is said to occur over four [4,5,6] phases: Phase 1 – initial phase. Contact exists between asperities on the two surfaces to be joined and heat is generated due to friction – see Fig. 1(a). The asperities soften and deform, increasing the true area of contact between the workpieces. Negligible axial shortening (burn-off) perpendicular to the direction of oscillation is observed during this phase
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