Energy and force analysis of Ti-6Al-4V linear friction welds for computational modeling input and validation data

The linear friction welding (LFW) process is finding increasing use as a manufacturing technology for the production of titanium alloy Ti-6Al-4V aerospace components. Computational models give an insight into the process, however, there is limited experimental data that can be used for either modeling inputs or validation. To address this problem, a design of experiments approach was used to investigate the influence of the LFW process inputs on various outputs for experimental Ti-6Al-4V welds. The finite element analysis software DEFORM was also used in conjunction with the experimental findings to investigate the heating of the workpieces. Key findings showed that the average interface force and coefficient of friction during each phase of the process were insensitive to the rubbing velocity; the coefficient of friction was not coulombic and varied between 0.3 and 1.3 depending on the process conditions; and the interface of the workpieces reached a temperature of approximately approximately 1273 K (1000 °C) at the end of phase 1. This work has enabled a greater insight into the underlying process physics and will aid future modeling investigations.EPSRC, Boeing Company, Welding Institut

Joining of dissimilar alloys Ti-6Al-4V and Ti-6Al-2Sn-4Zr-2Mo-0.1Si using linear friction welding

Dissimilar joints between Ti-6Al-4V (Ti-64) and Ti-6Al-2Sn-4Zr-2Mo-0.1Si (Ti-6242) were manufactured using linear friction welding. The weld quality, in terms of the microstructure and mechanical properties, was investigated after stress relief annealing (SRA) at 750 °C for 2 h and compared with the as-welded (AWed) results. The central weld zone (CWZ) microstructure in the AWed condition consisted of recrystallized prior-β grains with α' martensite, which transformed into an acicular α+β structure after SRA. The hardness in the AWed condition was highest in the CWZ and decreased sharply through the thermomechanically affected zones (TMAZ) to the parent materials (PMs). After SRA, the hardness of the CWZ decreased, mainly due to tempering of the α' martensite microstructure. Static tensile testing of the dissimilar welds in both the AWed and stress relief annealed (SRAed) conditions resulted in ductile fracture occurring exclusively in the Ti-6Al-4V side of the joint. The promising results on joining of Ti-64 to Ti-6242 provide valuable insight for tailoring performance of next-generation aero-engine products

An Integrated Modeling Approach for Predicting Process Maps of Residual Stress and Distortion in a Laser Weld: A Combined CFD–FE Methodology

Laser welding has become an important joining methodology within a number of industries for the structural joining of metallic parts. It offers a high power density welding capability which is desirable for deep weld sections, but is equally suited to performing thinner welded joints with sensible amendments to key process variables. However, as with any welding process, the introduction of severe thermal gradients at the weld line will inevitably lead to process-induced residual stress formation and distortions. Finite element (FE) predictions for weld simulation have been made within academia and industrial research for a number of years, although given the fluid nature of the molten weld pool, FE methodologies have limited capabilities. An improvement upon this established method would be to incorporate a computational fluid dynamics (CFD) model formulation prior to the FE model, to predict the weld pool shape and fluid flow, such that details can be fed into FE from CFD as a starting condition. The key outputs of residual stress and distortions predicted by the FE model can then be monitored against the process variables input to the model. Further, a link between the thermal results and the microstructural properties is of interest. Therefore, an empirical relationship between lamellar spacing and the cooling rate was developed and used to make predictions about the lamellar spacing for welds of different process parameters. Processing parameter combinations that lead to regions of high residual stress formation and high distortion have been determined, and the impact of processing parameters upon the predicted lamellar spacing has been presented

Reducing the environmental impact of surgery on a global scale: systematic review and co-prioritization with healthcare workers in 132 countries

Background Healthcare cannot achieve net-zero carbon without addressing operating theatres. The aim of this study was to prioritize feasible interventions to reduce the environmental impact of operating theatres. Methods This study adopted a four-phase Delphi consensus co-prioritization methodology. In phase 1, a systematic review of published interventions and global consultation of perioperative healthcare professionals were used to longlist interventions. In phase 2, iterative thematic analysis consolidated comparable interventions into a shortlist. In phase 3, the shortlist was co-prioritized based on patient and clinician views on acceptability, feasibility, and safety. In phase 4, ranked lists of interventions were presented by their relevance to high-income countries and low–middle-income countries. Results In phase 1, 43 interventions were identified, which had low uptake in practice according to 3042 professionals globally. In phase 2, a shortlist of 15 intervention domains was generated. In phase 3, interventions were deemed acceptable for more than 90 per cent of patients except for reducing general anaesthesia (84 per cent) and re-sterilization of ‘single-use’ consumables (86 per cent). In phase 4, the top three shortlisted interventions for high-income countries were: introducing recycling; reducing use of anaesthetic gases; and appropriate clinical waste processing. In phase 4, the top three shortlisted interventions for low–middle-income countries were: introducing reusable surgical devices; reducing use of consumables; and reducing the use of general anaesthesia. Conclusion This is a step toward environmentally sustainable operating environments with actionable interventions applicable to both high– and low–middle–income countries

Reducing the environmental impact of surgery on a global scale: systematic review and co-prioritization with healthcare workers in 132 countries

Abstract Background Healthcare cannot achieve net-zero carbon without addressing operating theatres. The aim of this study was to prioritize feasible interventions to reduce the environmental impact of operating theatres. Methods This study adopted a four-phase Delphi consensus co-prioritization methodology. In phase 1, a systematic review of published interventions and global consultation of perioperative healthcare professionals were used to longlist interventions. In phase 2, iterative thematic analysis consolidated comparable interventions into a shortlist. In phase 3, the shortlist was co-prioritized based on patient and clinician views on acceptability, feasibility, and safety. In phase 4, ranked lists of interventions were presented by their relevance to high-income countries and low–middle-income countries. Results In phase 1, 43 interventions were identified, which had low uptake in practice according to 3042 professionals globally. In phase 2, a shortlist of 15 intervention domains was generated. In phase 3, interventions were deemed acceptable for more than 90 per cent of patients except for reducing general anaesthesia (84 per cent) and re-sterilization of ‘single-use’ consumables (86 per cent). In phase 4, the top three shortlisted interventions for high-income countries were: introducing recycling; reducing use of anaesthetic gases; and appropriate clinical waste processing. In phase 4, the top three shortlisted interventions for low–middle-income countries were: introducing reusable surgical devices; reducing use of consumables; and reducing the use of general anaesthesia. Conclusion This is a step toward environmentally sustainable operating environments with actionable interventions applicable to both high– and low–middle–income countries

Titanium alloys research and development

NRC publication: Ye

Characterization of T1-6%AI-4%V/Tic particulate reinforced metal matrix composites consolidated by sintering and thermomechanical processing

TiC reinforcement particles were incorporated into a Ti-6%Al-4%V matrix and processed by two powder metallurgy techniques, namely elevated temperature pressureless sintering and hot deformation-assisted sintering (also known as hot pressing). For these composites, processing by sintering alone necessitated high temperatures (>1500\ub0C) for near-complete density consolidation, whilst the conditions for temperature and hold time were reduced (i.e. 1000\ub0C and 1/2 hour) through deformation-assisted sintering. [...]NRC publication: Ye

Characterization of electron beam welded AA2024

For aerospace manufacturing, the perseverance for improving performance (high strength to density ratio) and reducing weight and costs has motivated consideration of welding techniques applicable to aluminum alloys. During fusion welding of aluminum alloy (AA) 2024, the avoidance of defects (e.g., porosity, oxides, solidification cracking, undercutting) and the optimization of the microstructureproperty characteristics are of critical concern. In this work, AA2024 was electron beam (EB) welded as part of a study to determine the influence of parametric conditions on the characteristics of the weldment to optimize the joining process. Specifically, the evolution in the weld geometry, microstructure and mechanical properties was examined as a function of the process conditions, including beam current, beam focus, beam oscillation, and welding speed. For optimized parametric conditions, microstructural examination of the joints revealed narrow fusion and heat-affected zones comprising of dendritic structures without the occurrence of defects that enabled a maximized joint efficiency.Peer reviewed: YesNRC publication: Ye

Linear Friction Welding of Ti-6Al-4V: Processing, Microstructure and Mechanical Property Inter-relationships

The linear friction welding behavior of Ti-6Al-4V was investigated using varying processing conditions of frequency (15 to 70 Hz), amplitude (1 to 3 mm), pressure (50 to 90 MPa), and axial shortening (1 to 2 mm). Examination of linear friction welded Ti-6Al-4V using microscopic techniques indicated that the process requires certain critical conditions at the interface and its adjacent region to be reached for producing joints without structural defects along the weld centerline, such as voids or oxide inclusions. Characterization of the weldments included analysis of the microstructural features of the weld and thermomechanically affected zones (TMAZs) in relation to the parent material. It was observed that in the weld region, exposure to supertransus temperatures (>995 \ub0C) combined with hot-deformation working and rapid cooling after joining produced recrystallization of the beta grain structure that had a Widmanst\ue4tten alpha-beta transformation microstructure. In the TMAZ, the bimodal microstructure of the parent material was deformed and the presence of elongated alpha grains with broken beta-phase particles was established. Through examination of the mechanical properties, using microhardness and tensile testing, the integrity of the joints was determined in order to assess the impact of the various processing parameters and to define the optimum welding conditions.NRC publication: Ye