Multi-Length Scale Characterization of Microstructure Evolution and Its Consequence on Mechanical Properties in Dissimilar Friction Stir Welding of Titanium to Aluminum

Kar, Amlan; Suwas, Satyam; Kailas, Satish V.

doi:10.1007/s11661-019-05409-4

Cited by 40 publications

(35 citation statements)

References 82 publications

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“…It was predicted, from the systematic microstructural investigation of Ti, that the continuous fragmentation in Ti particles took place by the formation of micro-cracks due to the evolution of shear bands. Some identical results have been reported in the literature during the friction stir welding of Al to Ti [17]. However, the evolution of shear band formation in Ti has not been identified from the microstructural characterization.…”

Section: Introductionsupporting

confidence: 78%

“…Therefore, a systematic study could lead to elucidate the mechanism of microstructure development and the possible reason for formation of Ti particles and flakes, as discussed by Kar et al [17]. Fig.…”

Section: Electron Backscatter Diffractionmentioning

confidence: 98%

“…This process was used to separate the solid Ti from the liquid solution. Kar et al [17,19] proposed that these fine particles were either intercalated or intermetallics in composition and hence, chemical reaction and corrosion during dissolution of Al made these particles difficult for microstructural characterization and chemical analysis. The unreacted sample was examined by an Optical Microscope (OM) and a Scanning Electron Microscope (SEM).…”

Section: Microstructural Characterizationmentioning

confidence: 99%

“…It is important to note here that The microstructure of Ti base material comprises randomly oriented equiaxed grains with an average grain size of around 40 μm and it contains very small fraction of deformation twins. The EBSD data associated with Ti base material has been presented by Kar et al [17].…”

Section: Electron Backscatter Diffractionmentioning

confidence: 99%

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A new method to elucidate fracture mechanism and microstructure evolution in titanium during dissimilar friction stir welding of aluminum and titanium

Kar

Malopheyev

Mironov

et al. 2021

Materials Characterization

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In the friction stir welding (FSW) of dissimilar materials, the weld nugget exhibits composite properties and is composed of hard particles (high-strength material) distributed in a soft matrix material. The distribution of these particles influences the properties of the weld. Therefore, it is useful to characterize the deformation and fragmentation of the high-strength material from which they originate. In the current study, FSW of aluminum (Al) to titanium (Ti) was performed and a new technique was introduced to remove Al from the post-weld sample to characterize the deformation and fragmentation of Ti in the weld nugget. The post-weld sample showed that Ti particles were inhomogeneously distributed. It was understood that the plastic deformation of the Ti depends on its location of the weld. A detailed investigation revealed a number of fracture zones in titanium. A systematic analysis revealed the evolution of twins in Ti in the thermos-mechanically affected zone (TMAZ), whereas notwins and recrystallized grains were noticed on the Ti flake that was consolidated in the weld nugget. The Xray computed tomography (XCT) showed that Ti flakes were subjected to deformation and bending. Furthermore, it was noticed that the width of the flakes was not identical along their length and that the flakes were broken at the middle region into two parts. It can be concluded that Ti, at the interface and as flakes, was subjected to severe deformation at a lower homologous temperature that leads to the formation of adiabatic shear bands (ASBs). The local evolution of temperature within the ASBs was much higher than the general weld temperature, leading to the recrystallization of Ti at the interface. Moreover, ASBs are prone to crack nucleation and propagation; hence, particles with different morphology and sizes were noticed in the nugget zone. The distribution of particles was inhomogeneous due to variation in the particle size and complex mechanical mixing. The distribution of particles varied with location across the weld nugget. A homogeneous mechanical mixing was noticed at the center of the weld nugget due to complex material flow and distribution of finer particles. With this understanding of the deformation and fracture mechanism of titanium during dissimilar FSW of Al to Ti, it is possible to engineer the developed composites and/or weld nuggets of dissimilar materials to achieve the required combination of mechanical properties.

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Section: Introductionsupporting

confidence: 78%

Section: Electron Backscatter Diffractionmentioning

confidence: 98%

Section: Microstructural Characterizationmentioning

confidence: 99%

Section: Electron Backscatter Diffractionmentioning

confidence: 99%

See 2 more Smart Citations

A new method to elucidate fracture mechanism and microstructure evolution in titanium during dissimilar friction stir welding of aluminum and titanium

Kar

Malopheyev

Mironov

et al. 2021

Materials Characterization

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“…FSW was firstly developed to join precipitation hardening aluminium alloys, considered "unweldable" with conventional fusion welding processes. Currently, FSW tends to be a promising candidate for the production of hybrids structures, as shown by numerous recent studies devoted to the welding of dissimilar alloys (Simar and Avettand-Fenoel, 2017) such as aluminium to titanium (Kar et al, 2019), aluminium to copper (Kush and Vishvesh, 2016), aluminium to magnesium (Shah et al, 2018), aluminium to steel (Wan and Huang, 2018) and magnesium to steel (Singh et al, 2019).…”

Section: Introductionmentioning

confidence: 99%

Investigations on the material flow and the role of the resulting hooks on the mechanical behaviour of dissimilar friction stir welded Al2024-T3 to Ti-6Al-4V overlap joints

Geyer

Vidal

Pottier

et al. 2021

Journal of Materials Processing Technology

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HAL is a multi-disciplinary open access archive for the deposit and dissemination of scientific research documents, whether they are published or not. The documents may come from teaching and research institutions in France or abroad, or from public or private research centers. L'archive ouverte pluridisciplinaire HAL, est destinée au dépôt et à la diffusion de documents scientifiques de niveau recherche, publiés ou non, émanant des établissements d'enseignement et de recherche français ou étrangers, des laboratoires publics ou privés.Investigations on the material flow and the role of the resulting hooks on the mechanical behaviour of dissimilar friction stir welded Al2024-T3 to Ti-6Al-4V overlap joints

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Microstructural Evolution, Intermetallic Formation, and Mechanical Performance of Dissimilar Al6061–Ti6Al4V Static Shoulder Friction Stir Welds

Sundar. A,

Mugada,

Kumar

2023

Adv Eng Mater

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The present study focuses on achieving microstructural uniformity in dissimilar Al–Ti joints through static shoulder friction stir welding (SSFSW). This method restricts material mixing at the Al–Ti interface due to reduced shoulder action, resulting in peak temperatures of 317 °C (SSFSW) and 491 °C in conventional friction stir welding (CFSW). This reduction in heat input during SSFSW leads to decreased mechanical mixing, resulting in a thinner 2.169 μm intermetallic layer at interface of SSFSW compared to 5.485 μm in CFSW. The resulting weld nugget (WN) microstructure reveals the presence of Ti particles, intermetallic compounds, and fine Al‐associated grains. Rearrangement of dislocations through slip‐and‐climb mechanisms, along with distinct recrystallization processes in SSFSW, significantly reduces grain size within WN. The kernel average misorientation map highlights the presence of nonuniform dislocation concentrations at the interface of CFSW, attributed to the large Ti particles that impede the mobility of dislocations. As a result, the interface of CFSW is found to be the weakest among all the zones, eventually leading to the failure of the CFSW joint near the Ti interface after reaching an ultimate tensile strength of 259 MPa. In contrast, SSFSW welds achieve a higher tensile strength of 289 MPa.

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Multi-Length Scale Characterization of Microstructure Evolution and Its Consequence on Mechanical Properties in Dissimilar Friction Stir Welding of Titanium to Aluminum

Cited by 40 publications

References 82 publications

A new method to elucidate fracture mechanism and microstructure evolution in titanium during dissimilar friction stir welding of aluminum and titanium

A new method to elucidate fracture mechanism and microstructure evolution in titanium during dissimilar friction stir welding of aluminum and titanium

Investigations on the material flow and the role of the resulting hooks on the mechanical behaviour of dissimilar friction stir welded Al2024-T3 to Ti-6Al-4V overlap joints

Microstructural Evolution, Intermetallic Formation, and Mechanical Performance of Dissimilar Al6061–Ti6Al4V Static Shoulder Friction Stir Welds

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