This paper reports the results of a systematic investigation of residual stresses as a function of welding speed in a set of Ti-6Al-4V friction stir welds. The investigation focuses on residual stress but links these data with microstructural information derived from micrographs and hardness measurements as well as mechanical testing results. Residual stresses were determined using energy dispersive synchrotron X-ray diffraction, which allows phase specific stresses to be distinguished. The data presented in this paper demonstrate that welds with high tensile properties can be obtained, which also have relatively low peak tensile residual stress values of y30% of the tensile strength. The data also show a clear correlation between heat input and the width of the residual stress profile.
IntroductionTi-6Al-4V is an alpha-beta titanium alloy that offers a good combination of low density, high strength and excellent corrosion resistance, and has high biocompatibility. It is widely used in the aerospace sector, in high performance automotive parts, in chemical industries and in the manufacture of implantable medical devices and sensors, and accounts for more than 50% of all titanium alloy usage.While fusion welding techniques can be readily applied to Ti-6Al-4V alloys, their relatively poor thermal conductivity can cause problems through the effects of a high thermal gradient on residual stress, distortion and microstructural modification. Titanium alloys are also sensitive to the presence during welding of contaminants such as hydrogen, oxygen, iron, nitrogen and carbon, which can lead to porosity and hard inclusions. 1 Some difficulties are avoided by welding under inert gas shielded conditions and appropriate measures to avoid cross-contamination from steel manufacturing processes, e.g. a dedicated clean area for titanium.The development of solid state welding processes, such as friction stir welding (FSW), which are performed at reduced peak temperatures, offers the potential to reduce distortion and achieve lower residual stress values. Solid state stirring processes with their associated recrystallisation also lead to generally favourable microstructural modification, e.g. fine equiaxed grains in the weld nugget. The advantages of friction welding processes, in terms of weld preparation and post-weld dressing, microstructure and mechanical performance, have therefore led to significant interest in their application to certain high technology industrial sectors, e.g. transportation. [2][3][4][5] The focus of the present paper is to identify process parameters that give good tensile properties relative to parent plate values along with low levels of residual stress and hence which would give good static and dynamic performance in service. To this end, FS butt welds were made in 3 mm Ti-6Al-4V plate at five different tool travel speeds, ranging from 45 to 165 mm min 21 with a constant tool rotational speed of 550 rev min 21 , and the residual stresses were investigated non-destructively using synchrotron X-ray dif...