Advances in friction stir welding of Ti6Al4V alloy complex geometries: T-butt joint with complete penetration

• Published in: Archives of Civil and Mechanical Engineering Vol. 23; no. 3; p. 182
• Main Authors: Ambrosio, Danilo, Wagner, Vincent, Vivas, Javier, Dessein, Gilles, Aldanondo, Egoitz, Cahuc, Olivier
• Format: Journal Article
• Language: English
• Published: London Springer London 28.06.2023; Springer Nature B.V
• Subjects: Aluminum alloys; Butt joints; Civil Engineering; Elongation; Engineering; Friction stir welding; High temperature; Mass production; Mechanical Engineering; Mechanical properties; Original Article; Oxidation; Quality assessment; Structural Materials; Tee joints; Thinning; Titanium alloys; Titanium base alloys; Tool wear; Wear rate; Weldability; Welded joints; Welding parameters; Titanium alloy; Mechanical properties; Microstructure; Friction stir welding; T-joint; Tool wear
• ISSN: 1644-9665; 2083-3318; 1644-9665
• DOI: 10.1007/s43452-023-00717-4

In this work, the friction stir weldability of Ti6Al4V T-joints has been investigated. Its aims are: (i) to study the influence of tool and welding parameters on weld quality, (ii) to assess the joints’ mechanical strength to foresee future applications, and (iii) to characterize Co-based FSW tools’ wear by following the wear during the tests. Welds’ defectivity is studied by cross-section macrographies analysis. Independently from welding parameters and tools, internal voids are avoided, and a suitable weldability window is identified. Microstructure observations have corroborated temperatures below the β -transus point even in the nugget zone, guaranteeing joints’ maximum mechanical strengths at 96% and 87% of the base material for UTS and Y, respectively. Contrarily, elongation at break is very low, without reaching 20% of the base material. The failure is linked to section thinning and kissing bond defects at the joints’ corners. Additionally, tool wear proved to be a critical issue while friction stir welding Ti6Al4V. The inner part of the shoulder is the most sensitive to wear. The consequent high wear rate might be a problem for mass production. The work established the pertinence of assembling complex geometries of Ti6Al4V using friction stir welding, considering weld quality and the mechanical strength achieved. However, critical factors such as section thinning, kissing bond, and tool wear must be carefully addressed to avoid joints’ low elongation at break and to guarantee their mechanical strength.