Modelling the influence of the process inputs on the removal of surface contaminants from Ti-6Al-4V linear friction welds

The linear friction welding (LFW) process is finding increasing interest from industry for the fabrication of near-net-shape, titanium alloy Ti–6Al–4V, aerospace components. Currently, the removal of surface contaminants, such as oxides and foreign particles, from the weld interface into the flash is not fully understood. To address this problem, two-dimensional (2D) computational models were developed using the finite element analysis (FEA) software DEFORM and validated with experiments. The key findings showed that the welds made with higher applied forces required less burn-off to completely remove the surface contaminants from the interface into the flash; the interface temperature increased as the applied force was decreased or the rubbing velocity increased; and the boundary temperature between the rapid flash formation and negligible material flow was approximately 970 °C. An understanding of these phenomena is of particular interest for the industrialisation of near-net-shape titanium alloy aerospace components.EPSRC, Boeing Company, Welding Institut

Modelling of the workpiece geometry effects on Ti–6Al–4V linear friction welds

Linear friction welding (LFW) is a solid-state joining process that is finding increasing interest from industry for the fabrication of titanium alloy (Ti–6Al–4V) preforms. Currently, the effects of the workpiece geometry on the thermal fields, material flow and interface contaminant removal during processing are not fully understood. To address this problem, two-dimensional (2D) computational models were developed using the finite element analysis (FEA) software DEFORM and validated with experiments. A key finding was that the width of the workpieces in the direction of oscillation (in-plane width) had a much greater effect on the experimental weld outputs than the cross-sectional area. According to the validated models, a decrease of the in-plane width increased the burn-off rate whilst decreasing the interface temperature, TMAZ thickness and the burn-off required to remove the interface contaminants from the weld into the flash. Furthermore, the experimental weld interface consisted of a Widmanstätten microstructure, which became finer as the in-plane width was reduced. These findings have significant, practical benefits and may aid industrialisation of the LFW process.The authors would like to thank the Engineering and Physical Sciences Research Council (EPSRC), The Boeing Company and The Welding Institute (TWI) for funding the research presented in this paper

Wire + Arc Additive Manufacturing

Depositing large components (>10 kg) in titanium, aluminium, steel and other metals is possible using Wire + Arc Additive Manufacturing. This technology adopts arc welding tools and wire as feedstock for additive manufacturing purposes. High deposition rates, low material and equipment costs, and good structural integrity make Wire+Arc Additive Manufacturing a suitable candidate for replacing the current method of manufacturing from solid billets or large forgings, especially with regards to low and medium complexity parts. A variety of components have been successfully manufactured with this process, including Ti–6Al–4V spars and landing gear assemblies, aluminium wing ribs, steel wind tunnel models and cones. Strategies on how to manage residual stress, improve mechanical properties and eliminate defects such as porosity are suggested. Finally, the benefits of non-destructive testing, online monitoring and in situ machining are discussed

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

A pragmatic multi-centre randomised controlled trial of fluid loading in high-risk surgical patients undergoing major elective surgery - the FOCCUS study

Peer reviewedPublisher PD

Antimicrobials: A Global Alliance For Optimizing Their Rational Use In Intra-abdominal Infections (agora)

Intra-abdominal infections (IAI) are an important cause of morbidity and are frequently associated with poor prognosis, particularly in high-risk patients. The cornerstones in the management of complicated IAIs are timely effective source control with appropriate antimicrobial therapy. Empiric antimicrobial therapy is important in the management of intra-abdominal infections and must be broad enough to cover all likely organisms because inappropriate initial antimicrobial therapy is associated with poor patient outcomes and the development of bacterial resistance. The overuse of antimicrobials is widely accepted as a major driver of some emerging infections (such as C. difficile), the selection of resistant pathogens in individual patients, and for the continued development of antimicrobial resistance globally. The growing emergence of multi-drug resistant organisms and the limited development of new agents available to counteract them have caused an impending crisis with alarming implications, especially with regards to Gram-negative bacteria. An international task force from 79 different countries has joined this project by sharing a document on the rational use of antimicrobials for patients with IAIs. The project has been termed AGORA (Antimicrobials: A Global Alliance for Optimizing their Rational Use in Intra-Abdominal Infections). The authors hope that AGORA, involving many of the world's leading experts, can actively raise awareness in health workers and can improve prescribing behavior in treating IAIs.11NIAID NIH HHS [R01 AI117211