Computational modelling of dynamic recrystallisation of Ni-based superalloy during linear friction welding

Linear friction welding (LFW) is an advanced joining technology used for manufacturing and repairing complex assemblies like blade integrated disks (blisks) of aeroengines. This paper presents an integrated multiphysics computational modelling for predicting the thermomechanical-microstructural processes of IN718 alloy (at the component-scale) during LFW. Johnson–Mehl–Avrami-Kolmogorov (JMAK) model was implemented for predicting the dynamic recrystallisation of γ grain, which was coupled with thermomechanical modelling of the LFW process. The computational modelling results of this paper agree well with experimental results from the literature in terms of γ grain size and weld temperature. Twenty different LFW process parameter configurations were systematically analysed in the computations by using the integrated model. It was found that friction pressure was the most influential process parameter, which significantly affected the dynamic recrystallisation of γ grains and weld temperature during LFW. The integrated multiphysics computational modelling was employed to find the appropriate process window of IN718 LFW.

Monitoring Dynamic Recrystallisation in Bioresorbable Alloy Mg-1Zn-0.2Ca by Means of an In Situ Acoustic Emission Technique

The tensile behaviour of the biocompatible alloy Mg-1Zn-0.2Ca (in wt.%) in the fine-grained state, obtained by severe plastic deformation via multiaxial isothermal forging, has been investigated in a wide range of temperatures (20 ÷ 300) °C and strain rates (5 × 10−4 ÷ 2 × 10−2) s−1 with the measurements of acoustic emission (AE). The dependences of mechanical properties, including the yield stress, ultimate strength, ductility, and the strain-hardening rate, on the test temperature and strain rate, were obtained and discussed. It is shown for the first time that an acoustic emission method is an effective tool for in situ monitoring of the dynamic recrystallisation (DRX) process. The specific behaviour of the acoustic emission spectral density reflected by its median frequency as a function of strain at various temperatures can serve as an indicator of the DRX process’s completeness.

Microstructure, micro-inclusions, and mineralogy along the EGRIP ice core – Part 1: Localisation of inclusions and deformation patterns

Impurities deposited in polar ice enable the reconstruction of the atmospheric aerosol concentration of the past. At the same time they impact the physical properties of the ice itself such as its deformation behaviour. Impurities are thought to enhance ice deformation, but observations are ambiguous due to a shortage of comprehensive microstructural analyses. For the first time, we systematically analyse micro-inclusions in polar fast flowing ice, i.e. from the East Greenland Ice Core Project ice core drilled through the Northeast Greenland Ice Stream. In direct relation to the inclusions we derive the crystal preferred orientation, fabric, grain size, and microstructural features at 10 depths, covering the Holocene and Late Glacial. We use optical microscopy to create microstructure maps to analyse the in situ locations of inclusions in the polycrystalline, solid ice samples. Micro-inclusions are more variable in spatial distribution than previously observed and show various distributional patterns ranging from centimetre-thick layers to clusters and solitary particles, independent of depth. In half of all samples, micro-inclusions are more often located at or close to the grain boundaries by a slight margin (in the areas occupied by grain boundaries). Throughout all samples we find strong indications of dynamic recrystallisation, such as grain islands, bulging grains, and different types of sub-grain boundaries. We discuss the spatial variability in micro-inclusions, the link between spatial variability and mineralogy, and possible effects on the microstructure and deformation behaviour of the ice. Our results emphasise the need for holistic approaches in future studies, combining microstructure and impurity analysis.

Continuous drive friction welding of AISI 8630 low-alloy steel: experimental investigations on microstructure evolution and mechanical properties

Continuous drive friction welding (CDW) is a state-of-the-art solid-state welding technology for joining metallic components used in aerospace, oil and gas and power generation industries. This study summarises the results of mechanical and microstructural investigations on a modified AISI-8630 steel subjected to CDW. The effects of welding process parameters, including rotational speed, friction and forge forces, during CDW were explored to determine an optimum welding condition. The mechanical properties of the weld, and microstructural characteristics across different regions of the weld were measured and examined. The microstructure characterisation results suggest that the weld zone (WZ) experiences temperatures above Ac3 and the thermo-mechanically affected zone (TMAZ) experiences temperatures between Ac1 and Ac3 of the material. Investigations with electron backscatter diffraction (EBSD) demonstrated the occurrence of strain-induced dynamic recrystallisation in the weld. The weld demonstrated higher yield and ultimate tensile strengths at the expense of ductility and hardening capacity compared to the base metal (BM). The strain hardening profiles of the welds exhibited a dual-slopes characteristic, an indication of different levels of plastic deformation experienced by the constituent phases (i.e., martensite, bainite and ferrite) present in the microstructure. The maximum strength-to-ductility combination and static toughness values were obtained for the weld produced under the highest rotational speed, maximum friction force and an intermediate forge force of 1200-1400 rpm, 37.5-42.5 kN and 60-65 kN, respectively.

Characterisation of Microstructure and Mechanical Properties of Linear Friction Welded α+β Titanium Alloy to Nitinol

A variable area nozzle integrated into the design of a high-bypass-ratio turbofan engine effectively saves up to 10% in aircraft fuel consumption. Additionally, noise emissions can be lowered at airports during take-off and landing by having better control of the nozzle diameter. Shape memory capabilities of Nitinol alloys could be availed in the form of actuators in the construction of such a nozzle. However, these Nitinol actuators must be joined to Ti-6Al-4V, a prominent alloy making up most of the rest of the nozzle. Because of the huge differences in the physical and metallurgical properties of these alloys, fusion welding is not as effective as solid-state welding. In the current study, a linear friction welding process was adopted to join Ti-6Al-4V to Nitinol successfully. The effect of friction welding on the evolution of weld macro and microstructures; hardness and tensile properties were studied and discussed. The macrostructure of Ti-6Al-4V and Nitinol’s dissimilar joint revealed flash formation mainly on the Ti-6Al-4V side due to its reduced flow strength at high temperatures. Optical microstructures revealed fine grains in Ti-6Al-4V immediately adjacent to the interface due to dynamic recrystallisation and strain hardening effects. In contrast, Nitinol remained mostly unaffected. An intermetallic compound (Ti2Ni) was seen to have formed at the interface due to the extreme rubbing action, and these adversely influenced the tensile strength and elongation values of the joints.

Inter-relationship between microstructure evolution and mechanical properties in inertia friction welded 8630 low-alloy steel

The evolution of microstructure and mechanical properties in AISI 8630 low-alloy steel subjected to inertia friction welding (IFW) have been investigated. The effects of three critical process parameters, viz. rotational speed, friction and forge forces, during welding of tubular specimens were explored. The mechanical properties of these weld joints, including tensile and Charpy V-notch impact were studied for determining the optimum welding parameters. The weld joints exhibited higher yield strength, lower hardening capacity and ultimate tensile strength compared to base metal (BM). The maximum strength and ductility combination was achieved for the welds produced under a nominal weld speed of ~ 2900–3100 rpm, the highest friction force of ~ 680–720 kN, and the lowest axial forging load of ~ 560–600 kN. The measured hardness distribution depicted higher values for the weld zone (WZ) compared to the thermo-mechanically affected zone (TMAZ), heat-affected zone (HAZ) and BM, irrespective of the applied welding parameters. The substantial increase in the hardness of the WZ is due to the formation of microstructures that were dominated by martensite. The observed microstructural features, i.e. the fractions of martensite, bainite and ferrite, show that the temperature in the WZ and TMAZ was above Ac3, whereas that of the HAZ was below Ac1 during the IFW. The fracture surface of the tensile and impact-tested specimens exhibited the presence of dimples nucleating from the voids, thus indicating a ductile failure. EBSD maps of the WZ revealed the formation of subgrains inside the prior austenite grains, indicating the occurrence of continuous dynamic recrystallisation during the weld. Analysis of crystallographic texture indicated that the austenite microstructure (i.e. FCC) in both the WZ and TMAZ undergoes simple shear deformation during IFW.

Inferred basal friction and mass flux affected by crystal-orientation fabrics

We investigate the errors caused by neglecting the crystal-orientation fabric when inferring the basal friction coefficient field, and whether such errors can be alleviated by inferring an isotropic enhancement factor field to compensate for missing fabric information. We calculate the steady states that arise from ice flowing over a sticky spot and a bedrock bump using a vertical-slab numerical ice-flow model, consisting of a Weertman sliding law and the anisotropic Johnson flow law, coupled to a spectral fabric model of lattice rotation and dynamic recrystallisation. Given the steady or transient states as input for a canonical adjoint-based inversion, we find that Glen's isotropic flow law cannot necessarily be used to infer the true basal drag or friction coefficient field, which are obscured by the orientation fabric, thus potentially affecting vertically integrated mass fluxes. By inverting for an equivalent isotropic enhancement factor, a more accurate mass flux can be recovered, suggesting that joint inversions for basal friction and the isotropic flow-rate factor may be able to compensate for mechanical anisotropies caused by the fabric. Thus, in addition to other sources of rheological uncertainty, fabric might complicate attempts to relate subglacial conditions to basal properties inferred from an inversion relying on Glen's law.

Microstructure, Micro-inclusions and Mineralogy along the EGRIP ice core – Part 1: Localisation of inclusions and deformation patterns

Impurities deposited in polar ice allow the reconstruction of the atmospheric aerosol concentration of the past. At the same time they impact the physical properties of the ice itself such as its deformation behaviour. Impurities are thought to enhance ice deformation, but observations are ambiguous due to a shortage of comprehensive microstructural analyses. For the first time, we systematically analyse micro-inclusions in polar fast flowing ice, i.e. from the East Greenland Ice Core Project ice core drilled trough the Northeast Greenland Ice Stream. In direct relation to the inclusions we derive the crystal-preferred orientation, fabric, grain size, and microstructural features at ten depths, covering the Holocene and Late Glacial. We use optical microscopy to create microstructure maps to analyse the in situ locations of inclusions in the polycrystalline, solid ice samples. Micro-inclusions are more variable in spatial distribution than previously observed, and show various distributional patterns ranging from centimetre-thick layers to clusters and solitary particles, independent of depth. Analysing the area occupied by grain boundaries in the respective samples shows that micro-inclusions are slightly more often located at or close to grain boundaries in half of all samples. Throughout all samples we find strong indications of dynamic recrystallisation, such as grain islands, bulging grains and different types of subgrain boundaries. We discuss the spatial variability of micro-inclusions, the link between spatial variability and mineralogy, and possible effects on the microstructure and deformation behaviour of the ice. Our results emphasise the need for holistic approaches in future studies, combining microstructure and impurity analysis.

Remanufacturing the AA5052 GTAW Welds Using Friction Stir Processing

Progress in sustainable manufacturing is a crucial element to minimise negative environmental impacts. The conventional fusion weld process used to join aluminium alloys resulted in coarse grain structure, inevitable defects, and severe joint softening. Friction stir processing (FSP) has the potential to modify the microstructure of materials in joint structure and improve the mechanical properties. In this investigation, the effect of friction stir post–processing was evaluated to study the microstructural characteristics and mechanical properties of GTAW (gas tungsten arc welding) welds in the aluminium 5052 alloy. During FSP, the grains’ dendritic microstructure was destroyed, and the dynamic recrystallisation resulted in a very fine and equiaxed grains structure in the fusion zone. The hardness of the friction-stir-processed welds significantly improved because of microstructure grain refinement. The processed joint demonstrated higher ultimate tensile and yield strength (~275 MPa and 221 MPa, respectively) and superior elongation (31.1%) compared to the unprocessed weld; at the same time, the mechanical strength (yield and ultimate tensile) is similar to that of the base metal.