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.

Justification for the use of Markovian Langevin statistics in the modelling of activated surface diffusion.

Low temperature surface diffusion is driven by the thermally activated hopping of adatoms between adsorption sites. Helium spin-echo techniques, capable of measuring the sub-picosecond motion of individual adatoms, have enabled the bench-marking of many important adsorbate-substrate properties. The well-known Markovian Langevin equation has emerged as the standard tool for the interpretation of such experimental data, replacing adatom-substrate interactions with stochastic white noise and linear friction. However, the consequences of ignoring the colored noise spectrum and non-linearities inherent to surface systems are not known. Through the computational study of three alternative models of adatom motion, we show that the hopping rate and jump distributions of an adatom are fixed to within a few percent by the potential energy surface and a new generalized energy exchange rate parameter alone, independent of the model used. This result justifies the use of the Markovian Langevin equation, regardless of the true statistical nature of adatom forces, provided results are quoted in terms of the new energy exchange rate parameter. Moreover, numerous mechanisms for the effect of noise correlations and non-linear friction on the energy exchange rate are proposed which likely contribute to activated surface diffusion and activated processes more generally.

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.

Linear friction tester design and validation

Due to the complexity of friction phenomena, empirical analysis is the best way to predict the friction coefficient. To accomplish this, laboratory test rigs are needed. Although a rotary dynamic friction test bed was available to the authors, it had its limitations, such as low speed, inducement of lateral force, and the limitation of testing samples with different shapes. This paper will explain the process of designing and manufacturing a novel test setup for measuring friction and wear of the tire. The newly designed test rig can apply dynamic loading during the tests, and it can automatically measure the wear rate and temperature between cycles. In addition, it can be used for measuring the wear rate of rubber samples sliding on different types of surfaces. Therefore, experiments can be run under more controlled conditions. The designed linear friction tester can slide flat and round rubber samples approximately three meters across a large flat surface. The frictional force of rubber samples can be measured for various normal loads, velocities, and surface conditions. The new setup can automatically control the applied normal load on the sample using proportional–integral–derivative controller control. The important difference between this novel design and the existing testers used by other researchers is implementing the ball screw technology and the servo motor with high accuracy encoder to achieve highly accurate test results. In this design, the new mechanism for the ball screw is designed to increase the speed limit and eliminating vibrations while keeping the precision. In addition, in this design, the sample's mass can be measured automatically after each test cycle, thus providing a measure of the rate of wear of the rubber. In this study, the data collected by the linear friction tester is validated by comparing the data to the data collected by the dynamic friction tester (a validated rotary friction tester that exists in CenTiRe Lab). The data collected by the new setup was later used to benchmark the Persson analytical friction model.