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

A literature review of Ti-6Al-4V linear friction welding

Linear friction welding (LFW) is a solid-state joining process that is an established technology for the fabrication of titanium alloy bladed disks (blisks) in aero-engines. Owing to the economic benefits, LFW has been identified as a technology capable of manufacturing Ti-6Al-4V aircraft structural components. However, LFW of Ti-6Al-4V has seen limited industrial implementation outside of blisk manufacture, which is partly due to the knowledge and benefits of the process being widely unknown. This article provides a review of the published works up-to-date on the subject to identify the “state-of-the-art”. First, the background, fundamentals, advantages and industrial applications of the process are described. This is followed by a description of the microstructure, mechanical properties, flash morphology, interface contaminant removal, residual stresses and energy usage of Ti-6Al-4V linear friction welds. A brief discussion on the machine tooling effects is also included. Next, the work on analytical and numerical modelling is discussed. Finally, the conclusions of the review are presented, which include practical implications for the manufacturing sector and recommendations for further research and development. The purpose of this article is to inform industry and academia of the benefits of LFW so that the process may be better exploited

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

Value of ultrasonography as a marker of early response to abatacept in patients with rheumatoid arthritis and an inadequate response to methotrexate: results from the APPRAISE study

Objectives: To study the responsiveness of a combined power Doppler and greyscale ultrasound (PDUS) score for assessing synovitis in biologic-naïve patients with rheumatoid arthritis (RA) starting abatacept plus methotrexate (MTX). Methods: In this open-label, multicentre, single-arm study, patients with RA (MTX inadequate responders) received intravenous abatacept (∼10 mg/kg) plus MTX for 24 weeks. A composite PDUS synovitis score, developed by the Outcome Measures in Rheumatology–European League Against Rheumatism (OMERACT–EULAR)-Ultrasound Task Force, was used to evaluate individual joints. The maximal score of each joint was added into a Global OMERACT–EULAR Synovitis Score (GLOESS) for bilateral metacarpophalangeal joints (MCPs) 2–5 (primary objective). The value of GLOESS containing other joint sets was explored, along with clinical efficacy. Results: Eighty-nine patients completed the 24-week treatment period. The earliest PDUS sign of improvement in synovitis was at week 1 (mean change in GLOESS (MCPs 2–5): −0.7 (95% CIs −1.2 to −0.1)), with continuous improvement to week 24. Early improvement was observed in the component scores (power Doppler signal at week 1, synovial hyperplasia at week 2, joint effusion at week 4). Comparable changes were observed for 22 paired joints and minimal joint subsets. Mean Disease Activity Score 28 (C reactive protein) was significantly reduced from weeks 1 to 24, reaching clinical meaningful improvement (change ≥1.2) at week 8. Conclusions: In this first international prospective study, the composite PDUS score is responsive to abatacept. GLOESS demonstrated the rapid onset of action of abatacept, regardless of the number of joints examined. Ultrasound is an objective tool to monitor patients with RA under treatment. Trial registration number: NCT00767325