Effects of electron beam welding parameters on the microstructure of titanium to aluminum alloy joints

Electron beam welding of titanium alloy to aluminum alloy was carried out by melting and melt-brazing to investigate the effects of welding parameters on microstructure of the joint. The results indicated that the joint of the specimen welded by melting was well-formed but contained a large amount of intermetallic compounds. These intermetallic compounds were mainly composed of brittle phases such as TiAl and TiAl3 that decreased the ductility of the joints and resulted in a tensile strength 50 % lower than that of the base metal. In the melt-brazing experiment, direct heat was applied to the aluminum alloy to melt the aluminum rather than the titanium alloy, creating a well-formed joint. The weld was mainly composed of Al element and only a 3 ~m thickness of intermetallic compounds formed near the fusion line at the Ti side. The ductility and the performauce of the joint were significantly improved compared with those of the melting-only joint. In addition, the tensile strength of the joint reached 80 % of that of the aluminum base metal.

Pulse-Impact on Microstructure of Liquid-Phase-Pulse-Impact Diffusion Welded Joints of Particle Reinforcement Aluminum Matrix Composites at Various Temperatures

Investigation was to study the influence of pulse-impact on microstructure of Liquid-Phase-Pulse-Impact Diffusion Welding (LPPIDW) welded joints of aluminum matrix composite SiCp/A356, SiCp/6061Al, Al2O3p/6061Al. Results showed that under the effect of pulse-impact: 1) the interface state between reinforcement particle (SiC, Al2O3) and matrix was prominently;2) the initial pernicious contact-state of reinforcement particles was changed from reinforcement (SiC, Al2O3)/reinforcement (SiC, Al2O3) to reinforcement (SiC, Al2O3)/matrix/ reinforcement (SiC, Al2O3);3) the density of dislocation in the matrix neighboring to and away from the interface in the matrix was higher than its parent composite;and 4) the intensively mutual entwisting of dislocation was occurred. Studies illustrated that: 1) deformation was mainly occurred in the matrix grain;and 2) under the effect of pulse-impact, the matrices around reinforcement (SiC, Al2O3) particles engendered intensive aberration offered a high density nucleus area for matrix crystal, which was in favor of forming nano-grains and improved the properties of the successfully welded composite joints.

Interfacial reaction control during pulsed argon arc welding of SiC_p/Al composites

The interfacial reaction control of SiC_p/2124Al composites was investigated during pulsed argon arc welding. Meanwhile, the mechanical properties, the metallographic structure and interfacial microstructure of the induced welding joint were tested and detected, respectively. The results reveal that the joint with excellent properties could be achieved by the proper selection of the special filling material and the addition of the pulse during welding. Moreover, the formation mechanism of the welding joint was discussed and the corresponding measures on further improving the quality of the welding joint of SiC_p/2124Al composites were put forward in the condition of pulsed argon arc welding.

Resistance welding of carbon fibre reinforced polyetheretherketone composites using metal mesh and PEI film

Weldability of polyetheretherketone(PEEK) with polyetherimide(PEI) is tested. And carbon fiber reinforced PEEK laminates are resistance welded using stainless steel mesh heating element. The effects of the welding time and welding pressure on the lap shear strength of joints are investigated. Results show that PEEK can heal with PEI well in welding condition and the lap shear strength of PEEK/CF(carbon fibre) joint increases linearly with welding time, but reaches a maximum value when welding pressure ranging from 0.3 MPa to 0.5 MPa with constant welding time. The fracture characteristics of surface are analyzed by SEM techniques, and four types of fracture modes of lap shear joints are suggested.

Influence of welding parameters on microstructure and mechanical properties of electron beam welded Ti60 to GH3128 joint with a Cu interlayer

Effects of welding parameters on the microstructure and mechanical properties of Ti/Cu/Ni joint welded by electron beam were investigated.High welding heat input increased the melting quantity of Ti60 titanium alloy and promoted the formation of Ti-Cu intermetallic compounds(IMC)such as Ti_(2)Cu and Ti_(3)Cu_(4),increasing the brittleness of the joints.Low welding heat input was not conducive to the complete melting of the copper interlayer,and the unmelted copper reduced the performance of the joints.Under the optimal welding parameters,Ti-Ni IMCs in the weld would be replaced by(Cu,Ni)solid solutions((Cu,Ni)_(ss)).However,Ti-Cu IMC layers cannot be eliminated entirely by changing the welding parameters.The maximum tensile strength of the joints was 201 MPa.The fracture of the joints occurred at the Ti-Cu IMC layer,which was a typical brittle fracture.

Understanding micro-diffusion bonding from the fabrication of B_4C/Ni composites

A Ni-B_4C macroscopic diffusion welding couple and a Ni-15 wt% B_4C composite fabricated by spark plasma sintering(SPS) were used to understand the micro-scale diffusion bonding between metals and ceramics. In the Ni-B_4C macroscopic diffusion welding couple a perfect diffusion welding joint was achieved. In the Ni-15 wt% B_4C sample, microstructure analyses demonstrated that loose structures occurred around the B_4C particles. Energy dispersive X-ray spectroscopy analyses revealed that during the SPS process, the process of diffusion bonding between Ni and B_4C particles can be divided into three stages. By employing a nano-indentation test, the room-temperature fracture toughness of the Ni matrix was found to be higher than that of the interface. The micro-diffusion bonding between Ni and B_4C particles is quite different from the Ni-B_4C reaction couple.

Laser welding process and strength enhancement of carbon fiber reinforced thermoplastic composites and metals dissimilar joint:A review

Carbon fiber reinforced thermoplastic composites(CFRTP)and metals hybrid structures have been widely used in aircraft lightweight manufacturing.However,due to the significant difference in physical and chemical properties between CFRTP and metals,there are lots of challenges to connect them with high quality.Laser welding has a good application prospect in CFRTP and metals connection,and a significant research progress has been made in the exploration of CFRTP-metal laser joining mechanism,joining process optimization,joining strength improvement and joining defects controlling.However,there are still some problems need to be solved for this technology application.In this paper,the research progress of CFRTP-metal laser joining was summarized in three major aspects:theoretical modeling and simulation analysis,process exploration and parameter optimization,joint performance improvement and process innovation.And,problems and challenges of this technology were discussed,and the outlook of this research was provided.

Comprehensive study of microstructure and mechanical properties of friction stir welded 5182-O/HC260YD+Z lap joint

The welding of aluminum(Al)and steel has attracted more and more interest due to the weight reduction trend in vehicle and aerospace manufacturing industries.5182-O/HC260YD+Z lap joint was produced by friction stir welding(FSW),and the microstructure and mechanical property of the joint were systemically characterized.The microstructure in horizontal direction of the Al and steel near interface was similar to their corresponding conventional friction stir welded joint.The joint was divided into stir zone of Al(ST-Al),stir zone of interface(ST-I),thermal-mechanically affected zone of steel(TMAZ-Fe)and base material of steel(BM-Fe)according to their distinct microstructure vertically.Three kinds of intermetallic compounds(IMCs)of FeAl_(3),FeAl and Fe_(3)Al were formed at the interface.The horizontal micro hardness distribution exhibited a hat shape and“M”shape in Al and steel,respectively.The hardest region of the joint was located at the ST-I,with a hardness of 175 HV−210 HV.The joint was fractured along the hook structure,with an average shear strength of 73.9 MPa.Fractural morphology of Al and steel indicted a cleavage fracture mode.

Effect of pulse parameters on microstructure of joint in laser beam welding for SiC_p/6063 composite

The restraint effects of pulse frequency and pulse duty cycle on the precipitates of harmful needle like Al 4C 3 phase were studied in CO 2 impulsed laser welding through the experiment on the SiC p/6063 composite, and the microstructures of the weld under the different process parameters (pulse time from 1 ms to 20 ms,duty cycle from 50% to 91%) were analyzed. In order to compare, CO 2 continuous laser was conducted under the same efficiency. The results demonstrate that the proper laser pulse frequency and duty cycle can restrain the formation of Al 4C 3 effectively. However, the burning loss of SiC is more serious and the fluidity of molten pool is less in continuous laser welding than in impulsed laser welding.

Effect of flame heating pass on microstructure and properties of A6N01 aluminum alloy welded joint

Flame heating combined with water cooling was used to straighten A6N01 aluminum alloy welded joint and effect of flame heating pass on its microstructure and mechanical properties was studied. Results showed that the flame induced the precipitation and growth of the Mg_2Si phase on the Al substrate for the thermal aging A6N01 aluminum alloy welded joints,thus it led the decrease of micro-hardness and tensile strength of the A6N01 aluminum alloy welded joint with the increase of the heating pass. However,the fatigue property of the flame heated joint was improved because the Mg_2Si precipitation hindered the initiation and propagation of the fatigue crack.

Microstructure and mechanical property of resistance spot welded joint of aluminum alloy to high strength steel with especial electrodes

Dissimilar material joining of 6008 aluminum alloy to H220 YD galvanized high strength steel was performed by resistance spot welding with especial electrodes that were a flat tip electrode against the steel surface and a domed tip electrode upon the aluminum alloy surface. An intermetallic compound layer composed of Fe2Al5 and FeAl3 was formed at the steel/ aluminum interface in the welded joint. The thickness of the intermetallic compound layer increased with increasing welding current and welding time, and the maximum thickness being 7. 0 μm was obtained at 25 kA and 300 ms. The weld nugget diameter and tensile shear load of the welded joint had increased tendencies first with increasing welding current （ 18 -22 kA） and welding time （ 50 - 300 ms）, then changed little with further increasing welding current （ 22 - 25 kA） and welding time （300 -400 ms）. The maximum tensile shear load reached 5.4 kN at 22 kA and 300 ms. The welded joint fractured through brittle intermetallic compound layer and aluminum alloy nugget.

Effect of tool pin profile on microstructure and tensile properties of friction stir welded dissimilar AA 6061e AA 5086 aluminium alloy joints

Joints between two different grades of aluminium alloys are need of the hour in many light weight military structures.In this investigation,an attempt has been made to join the heat treatable(AA 6061) and non-heat treatable(AA 5086) aluminium alloys by friction stir welding(FSW)process using three different tool pin profiles like straight cylindrical,taper cylindrical and threaded cylindrical.The microstructures of various regions were observed and analyzed by means of optical and scanning electron microscope.The tensile properties and microhardness were evaluated for the welded joint.From this investigation it is founded that the use of threaded pin profile of tool contributes to better flow of materials between two alloys and the generation of defect free stir zone.It also resulted in higher hardness values of 83 HV in the stir zone and higher tensile strength of 169 MPa compared to other two profiles.The increase in hardness is attributed to the formation of fine grains and intermetallics in the stir zone,and in addition,the reduced size of weaker regions,such as TMAZ and HAZ regions,results in higher tensile properties.

Multi-objective optimization of gas metal arc welding parameters and sequences for low-carbon steel (Q345D) T-joints

Q345D high-quality low-carbon steel has been extensively employed in structures with stringent weld- ing quality requirements. A multi-objective optimization of welding stress and deformation was presented to design reasonable values of gas metal arc welding parameters and sequences of Q345D T-joints. The optimized factors included continuous variables （welding current （I）, welding voltage （U） ahd welding speed （V）） and discrete variables （welding sequence （S） and welding direc- tion （D））. The concepts of the pointer and stack in Visual Basic （VB） and the interpolation method were introduced to optimize the variables. The optimization objectives included the different combina- tions of the angular distortion and transverse welding stress along the transverse and longitudinal dis- tributions. Based on the design of experiments （DOE） and the polynomial regression （PR） model, the finite element （FE） results of the T-joint were used to establish the mathematical models. The Pareto front and the compromise solutions were obtained by using a multi-objective particle swarm optimization （MOPSO） algorithm. The optimal results were validated by the corresponding results of the FE method, and the error between the FE results and the two-objective results as well as that be-tween the FE results and the three-objective optimization results were less than 17.2% and 21.5%, respectively. The influence and setting regularity of different factors were discussed according to the compromise solutions.

Microstructure and properties of 7A52 Al alloy welded joint

7A52 Al alloy plate aged at 105 ℃ for 8 h and then at 130 ℃ for 24 h was welded by means of TIG using Al- 6.3Mg-0.35Sc-0.1Zr-0.1Cr solder wire. Mechanical properties and microstructures of welded joint were studied. There are two obviously soft areas in the welded joint, welding seam and over-aging zone. The mechanical properties of welded joint are that σb is 358 MPa, σ0.2 is 238 MPa and δ5 is 6.6%. 75.6% of welding coefficient can be achieved. The addition of scandium leads to very significant grain refinement in the fusion zone, which results in a reduction in solidification cracking tendency. The solidification cracking isn’t observed.

Microstructure and mechanical properties of the welding joint filled with microalloying 5183 aluminum welding wires

In this study, 7A52 aluminum alloy sheets of 4 mm in thickness were welded by tungsten inert gas welding using microalloying welding wires containing traces of Zr and Er. The influence of rare earth elements Zr and Er on the microstructure and mechanical properties of the welded joints was analyzed by optical microscopy, energy dispersive X-ray spectroscopy, transmission electron microscopy, hardness testing, and tensile mechanical properties testing. Systematic analyses indicate that the addition of trace amounts of Er and Zr leads to the formation of fine Al3Er, Al3Zr, and Al3（Zr,Er） phases that favor significant grain refinement in the weld zone. Besides, the tensile strength and hardness of the welded joints were obviously improved with the addition of Er and Zr, as evidenced by the increase in tensile strength and elongation by 40 MPa and 1.4%, respectively, and by the welding coefficient of 73%.

Diffusion bonding mechanism and microstructure ofwelded joint of aluminium matrix composite Al_2O_(3p),/6061

Relationships between microstructures of welded joint and welding parameters or weld strength of aluminium matrix composite Al2O3p/6061 subjected to diffusion welding were studied. The results are as follows: key factor affecting strength of welded joint is oxide in the weld zone. The existence of oxide in the welded joint not only hinders the diffusion of the matrix atoms, but also destroys the good interface between the matrix and the reinforced phase. The oxides turn into fine particles from film with increasing welding temperature, and the destroying effect on welded joint decreases, which increases the strength of the welded joint. On the basis of this, the diffusion welding of aluminium matrix composite Al2O3p/6061 was successfully realized.

Microstructures and properties of tungsten inert gas welding joint of super-eutectic ZA alloy

The microstructure of butt welding joint of supper eutectic ZA alloy in TIG welding was analyzed through optical microscope and transmission electronic microscope. The results show that the weld seam microstructure is fine and mainly composed of columnar crystals and minor equiaxed crystals, the microstructure in the zone near the weld seam is coarse columnar crystals, and the grain in heat affected zone does not grow markedly. The joint microstructure at room temperature is consisted of β phase (rich Al), η Zn, ε phase (CuZn compound), Al 4Cu 9 and other compounds. The hardness of the weld bond area and the tensile strength of the joint are a little higher than that of base materials. The specific elongation of the weld and bond area is a little lower than those of base materials. [

Interfacial microstructure evolution of 12Cr1MoV/TP347H dissimilar steel welded joints during aging

The interfacial microstructure evolution of 12Cr1MoV/TP347H dissimilar steel welded joints with a nickel-based filler metal during aging was studied in detail to elucidate the mechanism of premature failures of this kind of joints.The results showed that not only a band of granular Cr_(23)C_(6)carbides were formed along the fusion boundary in the ferritic steel during aging,but also a large number of granular or plate-like Cr_(23)C_(6)carbides,which have a cube-cube orientation relationship with the matrix,were also precipitated on the weld metal side of the fu-sion boundary,making this zone be etched more easily than the other zone and become a dark etched band.Stacking faults were found in some Cr_(23)C_(6)carbides.In the as-welded state,deformation twins were observed in the weld metal with a fully austenitic structure.The peak micro-hardness was shifted from the ferritic steel side to the weld metal side of the fusion boundary after aging and the peak value increased signific-antly.Based on the experimental results,a mechanism of premature failures of the joints was proposed.

Effect of Post-weld Heat Treatment on Microstructure and Fracture Toughness of 30CrMnSiNi2A Steel Welded Joints

The electron beam local post-weld heat treatment (EBLPWHT) is a rather new method that provides the advantages of high precision, flexibility and efficiency, energy saving and higher productivity. This paper studies the effect of two post-weld heat treatment processes on the microstructure, mechanical properties and fracture toughness of an electron beam welded joints in 30CrMnSiNi2A steel. EBLPWHT, in a vacuum chamber, immediately after welding and a traditional furnace whole post-weld heat treatment (FWPWHT) were compared. The experimental results show that, after EBLPWHT treatment, the main microstructure of weld was changed from coarse acicular martensite into lath martensite, HAZ was changed from lath martensite, bainite into lower bainite, and base metal was changed from ferrite and pearlite into upper bainite and residual austenite. The microstructures of different zones of joints in FWPWHT condition were tempered sorbite. The properties of welded joints can be improved by the EBLPWHT in some extent, and especially largely for the fracture toughness of welded joints. However the value of fracture toughness of base metal is comparatively low, so appropriate heat treatment parameters should be explored in the future.

Effects of strength matching and crack depth on the fracture parameters for welded joints

Fracture parameters of welded joints with different strength matching and crack depth in weld metal are investigated by using the methods of elastoplastic finite element analysis and three point bend specimen test. The results show that for shallow crack, the plastic zone turns large in loading process, and the fracture toughness turns high. The extent of the plastic zone of overmatched joint is larger than that of undermatched joint because it will extends to parent metal from the weld metal in loading process for the same CTOD value. The plastic zone of undermatched joint is restricted within the weld, and the size of that is small. Overmatched joint shows the fracture behaviour of shallow crack may more easily than the undermatched joint, while the two sorts of joint specimens have the same crack depth. Therefore, the fracture-resistant capability of overmatched weld is better than that of undermatched weld. when the toughness of weld metals is similar for both overmatched and undermatched joints.