Modelling the influence of the process inputs on the removal of surface contaminants from Ti–6Al–4V linear friction welds

Abstract

a b s t r a c tThe 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.

3D modelling of Ti–6Al–4V linear friction welds

“…An increasingly popular approach for the modelling of titanium alloysspecifically Ti-6Al-4V -is the 'single-body approach' [1,5,13,25,26]. This approach is based on the following theory: Before phase 2 takes place, there is negligible macroscopic plastic deformation.…”

Microstructure and Mechanical Properties of Friction Welding Joints with Dissimilar Titanium Alloys

“…Interrelationship of microstructure and mechanical properties of LFW titanium joint was also investigated [27]. In addition, to predicting various weld responses, such as thermal fields and microstructural evolution, a great number of finite element models were established and the predictions of the models were found to be in good agreement with the experimental results [28][29][30][31].…”

3D Modelling of Flash Formation in Linear Friction Welded 30CrNiMo8 Steel Chain

“…'Hero' is the designation given to the chains joined with this process. Due to the rapid nature of the process, modelling is often used to describe the weld phenomena in terms of flash formation, surface self-cleaning ability, and thermal histories in order to provide as much insight as possible, which would not be possible with experimental work alone [10][11][12]. Despite this, 2D modelling has been of preference for the majority of published work, regarding the fact that it provides considerable information on the LFW process, without the significant computational effort drawback experienced in 3D modelling.…”

“…Despite this, 2D modelling has been of preference for the majority of published work, regarding the fact that it provides considerable information on the LFW process, without the significant computational effort drawback experienced in 3D modelling. However, 2D models are unable to replicate the flash formation in the direction perpendicular to the oscillation direction [10]. As a result, significant effort has been done in recent years to develop 3D LFW models.…”