Michael Preuss

Microstructure, mechanical properties and residual stresses as a function of welding speed in aluminium AA5083 friction stir welds

Friction stir welding (FSW), like other friction welding techniques, has the advantage that many of the welding parameters, e.g. tool design, rotation speed and translation speed, can be controlled in a precise manner, thus controlling the energy input into the system. However, the effect of different welding speeds on the weld properties remains an area of uncertainty. In this paper, we report the results of microstructural, mechanical property and residual stress investigations of four aluminium AA5083 friction stir welds produced under varying conditions. It was found that the weld properties were dominated by the thermal input rather than the mechanical deformation by the tool.

Methods for obtaining the strain-free lattice parameter when using diffraction to determine residual stress

The determination of residual stress by diffraction depends on the correct measurement of the strain-free lattice spacing d(hkl)(0), or alternatively the enforcement of some assumption about the state of strain or stress within the body. It often represents the largest uncertainty in residual stress measurements since there are many ways in which the strain-free lattice spacing can vary in ways that are unrelated to stress. Since reducing this uncertainty is critical to improving the reliability of stress measurements, this aspect needs to be addressed, but it is often inadequately considered by experimenters. Many different practical strategies for the determining of d(hkl)(0) or d(ref) have been developed, some well known, others less so. These are brought together here and are critically reviewed. In practice, the best method will vary depending on the particular application under consideration. Consequently, situations for which each method are appropriate are identified with reference to practical examples.

High-temperature strain field measurement using digital image correlation:

A method is presented for obtaining good images of sample surfaces at high temperatures, suitable for strain measurement, by digital image correlation (DIC) without the use of surface markers or speckles. This is accomplished by suppressing black-body radiation through the use of filters and blue illumination. Using only relatively low levels of illumination the method is demonstrated to be capable of providing accurate DIC measurements up to 1100 °C, and the potential to monitor strains to 1400 °C is identified. The capability of the method is demonstrated by measuring the Youngs modulus and coefficient of thermal expansion of a nickel-base superalloy at temperatures from ambient to 1000 °C; two parameters that are well established in the literature and that require high strain sensitivity for their reliable determination.

X-ray microtomography studies of localised corrosion and transitions to stress corrosion cracking

Abstract Two forms of high resolution X-ray tomographic experiments (i.e. synchrotron based X-ray microtomography and desktop microfocus computed X-ray tomography) are demonstrated in the present paper to illustrate the wide application of these techniques for qualitative and quantitative studies of localised corrosion and environmentally assisted cracking. Specifically, synchrotron based X-ray tomography was used to investigate the localised corrosion morphology within aluminium specimens when exposed in situ to a chloride environment while microfocus computed X-ray tomography was used to investigate the morphology and quantify the transition from localised corrosion to stress corrosion cracking in steel specimens exposed ex situ to a simulated corrosive condensate environment.

Solid state joining of metals by linear friction welding: a literature review

Abstract Linear friction welding (LFW) is a solid state joining process in which a joint between two metals can be formed through the intimate contact of a plasticised layer at the interface of the adjoining specimens. This plasticised layer is created through a combination of frictional heating, which occurs as a result of pushing a stationary workpiece against one that is moving in a linear reciprocating manner, and applied force. The process is currently established as a niche technology for the fabrication of titanium alloy bladed disc (blisk) assemblies in aeroengines, and is being developed for nickel based superalloy assemblies. However, interest is growing in utilising the process in a wider range of applications that also employ non-aeroengine metallic materials. Therefore, it is the objective of this report to provide a broad view of the capabilities of the LFW process for joining metals. This review paper will cover relevant published work conducted to date on LFW. The basics of the process and the fundamental aspects of operating a LFW machine will first be described, followed by a description of the different materials that have been welded using the process. The review will then go on to describe the microstructural changes, including texture variations, and residual stresses that are produced as a result of the welding process.

Comparison of residual stresses in Ti–6Al–4V and Ti–6Al–2Sn–4Zr–2Mo linear friction welds

Abstract In this paper, the levels of residual stress in the vicinity of linear friction welds in Ti–6Al–4V (Ti-64), a conventional α–β titanium alloy, and Ti–6Al–2Sn–4Zr–2Mo (Ti-6242), a near α titanium alloy with higher temperature capability, are mapped and contrasted. The alloys have significantly different high temperature properties and the aim of this work was to investigate how this might affect their propensity to accumulate weld residual stresses and their response to post-weld heat treatment. Measurements are reported using high energy synchrotron X-ray diffraction and the results are compared to those made destructively using the contour method. The strain free lattice plane d 0 variation across the weld has been evaluated using the biaxial sin2Ψ technique with laboratory X-rays. It was found that failure to account for the d 0 variation across the weld line would have led to large errors in the peak tensile stresses. Contour method measurements show fairly good correlation with the diffraction results, although the stresses are underestimated. Possible reasons for the discrepancy are discussed. The peak tensile residual stresses introduced by the welding process were found to be greater for Ti-6242 (∼750 MPa) than for Ti-64 (∼650 MPa). Consistent with the higher temperature capability of the alloy, higher temperature post-weld heat treatments have been found to be necessary to relieve the stresses in the near α titanium alloy compared to the α+β titanium alloy.

Sic single fibre full-fragmentation during straining in a Ti-6Al-4V matrix studied by synchrotron X-rays

High spatial resolution synchrotron X-ray strain measurements and radiography/tomography have been combined to study the progressive fragmentation process during a single fibre full-fragmentation test. In this manner it has been possible to observe the fragmentation sequence and to determine the interfacial shear stress as a function of position along the fibre. The SCS-6 fibre failed after it was elastically strained locally to 1.5%. The interfacial frictional shear strength inferred from the longitudinal strain profile of the broken fibre was calculated to be around 200 MPa, whereas a conventional post mortem full fragmentation analysis based on the mean fragment length would have incorrectly given a value of ∼700 MPa. This is due to the degradation of the fibre strength after the initial fibre fracture event. After failure, interface sliding was observed along considerable lengths of the fibre matrix interface. Upon unloading some reverse frictional sliding was found to take place. The morphology of the fibre cracks as well as the occurrence of matrix cracks as the sample approaches saturation fragmentation were also determined from radiographic and tomographic images.

Residual Strain Measurement by Synchrotron Diffraction

Third generation synchrotron X-ray sources such as the European Synchrotron Radiation Facility and the Advanced Photon Source (USA) have made very intense beams of very high energy X-rays available for the first time. At energies in excess of 60 keV penetration lengths of the order of centimetres are possible in most engineering materials. The associated low scattering angles limit the strain measurement directions available at depth. Gauge dimensions as small as microns and sub-second measurement times give the technique unique characteristics, making 2 and 3 dimensional strain mapping economically feasible. The current state of the art is reviewed and the potential assessed, primarily using illustrative case studies made at the ESRF. These include the measurement of near surface strains caused by peening, TIG welding stresses for the development of finite element models, the mapping of crack bridging during fatigue crack growth in Ti/SiC fibre composites and crack field mapping in 3D.

Linear and rotary friction welding review

Friction welding (FW) is a high quality, nominally solid-state joining process, which produces welds of high structural integrity. Rotary friction welding (RFW) is the most commonly used form of FW, while linear friction welding (LFW) is a relatively new method being used mainly for the production of integrally bladed disc (blisk) assemblies in the aircraft engine industry. Numerous similar and dissimilar joints of structural metallic materials have been welded with RFW and LFW. In this review, the current state of understanding and development of RFW and LFW is presented. Particular emphasis is placed on the process parameters, joint microstructure, residual stresses, mechanical properties and their relationships. Finally, opportunities for further research and development of the RFW and LFW processes are identified.

X-ray tomographic imaging of Ti/SiC composites

In this paper, high‐resolution tomographic synchrotron X‐ray imaging is applied to study the occurrence and evolution of damage in Ti‐6Al‐4V/SCS6 SiC fibre composite materials. Three composite morphologies of increasing complexity have been studied, namely single fibre, single‐ply and multi‐ply composites. The single fibre composite was strained to full fibre fragmentation and the progressive introduction of damage monitored. For the single‐ply composite, damage was introduced deliberately by laser drilling to establish the effect of damaged fibres on their neighbours, whereas for the multi‐ply composite the morphology of a fibre bridging fatigue crack was studied. In addition to traditional mode I fibre fractures, subsequent fibre wedge cracks were observed presumably nucleating from damage introduced into the fibre surface by the first fracture event. In addition to these crack morphologies, spiral defects were observed for the single ply during failure. Finally, for the multi‐ply composite, the matrix crack front showed a number of characteristic features, including advancement in fibre‐free regions, crack bifurcation near fibres and different crack plane heights either side of a fibre.