A Numerical Simulation Method Considering Solid Phase Transformation and the Experimental Verification of Ti6Al4V Titanium Alloy Sheet Welding Processes
Abstract
:1. Introduction
2. Materials and Methods
2.1. Material Performance of Ti6Al4V
2.2. The LBW and TIG Welding Processes of Ti6Al4V Titanium Alloy
2.3. Experiment on Microstructure and Macro Mechanical Properties
2.3.1. Hardness Measurement and Microstructure Observation
2.3.2. Measurement of Residual Stresses
3. Numerical Simulation Method of Welding Processes
3.1. Numerical Calculation of Welding Temperature Field
3.2. Numerical Calculation of Welding Residual Stress
3.3. Solid Phase Transformation of Titanium Alloy during Welding
- Theoretical model of solid phase transformation
- 2
- Solid phase transformation model of titanium alloy welding
3.4. Implementation of Numerical Simulation and Parameters Calibration
4. Results and Discussion
4.1. Microstructure Observation of Welded Joints
4.2. Simulation Results of Phase Volume Fraction Based on Ti6Al4V Phase Transition Model
4.2.1. Simulation Results of Temperature Field
4.2.2. Simulation Results of Phase Volume Fraction
4.3. Verification of Consistency of Hardness Distribution and Phase Volume Fraction Distribution of Welded Joints
4.4. Verification of Simulation Results of Residual Stress and Deformation Considering Solid-State Phase Transformation
4.4.1. Influence of Welding Technology on Residual Stress
4.4.2. Influence of Welding Technology on Deformation
5. Conclusions
- (1)
- Although the distribution of phase composition and phase volume fraction of LBW- and TIG-welded joints by numerical simulation cannot fully reflect the complexity of microstructure evolution, it can express the approximate distribution trend of phases: For the LBW welded joint, the FZ and FZ/HAZ interfaces are mainly martensite α′ phase, while the HAZ/PM interface retains a certain amount of residue β phase. For the TIG-welded joint, the FZ is partial martensite α′ phase, and the HAZ/PM interface retains a large amount of residual β phase. Therefore, the numerical method established in this paper can obtain useful information of phase composition and distribution of welded joints with different welding processes (LBW and TIG welding) in the form of scalar fields.
- (2)
- Because the thermal expansion coefficient and unit cell volume of the α phase and β phase are different, the numerical simulation results of residual stress and deformation will be affected after considering the phase composition and phase volume fraction distribution of welded joints. For LBW- and TIG-welded joints, the phase transformation process from the β phase to the martensitic α′ phase or to the α phase is a process of material volume expansion. Therefore, during welding, the FZ area expands and the HAZ/PM area shrinks, resulting in tensile stress in the FZ area and compressive stress in the HAZ/PM narrow area.
- (3)
- In extension, through the research results of LBW- and TIG-welded joints, the scalar fields of the phase volume fraction and residual stress can be used as the characteristic quantities of the welding process, and the scalar fields of the phase volume fraction and residual stress can be introduced into the numerical analysis of structural fracture failure as welding process factors, so the influence of the welding process on structural fracture failures can be considered.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Ti | Al | V | Fe | C | N | H | O |
---|---|---|---|---|---|---|---|
rest | 6.5 | 4.4 | 0.30 | 0.10 | 0.05 | 0.015 | 0.20 |
Current | Pulse Width | Voltage (V) | Welding Speed (mm/min) | Arc Length (mm) | Shielding Gas | Top Width of FZ (mm) | Bottom Width of FZ (mm) | ||
---|---|---|---|---|---|---|---|---|---|
Primary (A) | Background (A) | High (ms) | Low (ms) | ||||||
32 | 16 | 8 | 4 | 10 | 32.5 | 4 | Argon | 5.2 | 3.8 |
Power (kW) | Pulse Duration (ms) | Pulse Frequency (Hz) | Welding Speed (mm/min) | Defocus Distance (mm) | Shielding Gas | Top Width of FZ (mm) | Bottom Width of FZ (mm) |
---|---|---|---|---|---|---|---|
0.8 | 8 | 8 | 160 | 0 | Argon | 2.35 | 1.75 |
Distance (mm) | 0 | 0.5 | 1.0 | 1.5 | 2.0 | 2.5 | 3.0 | 3.5 | 4.0 | 4.5 | 5.0 | 5.5 |
---|---|---|---|---|---|---|---|---|---|---|---|---|
Hardness (HV) | 369.8 | 383.1 | 369.2 | 382.1 | 367.0 | 367.1 | 377.2 | 366.9 | 362.7 | 350.9 | 356.8 | 358.0 |
Distance (mm) | 6.0 | 6.5 | 7.0 | 7.5 | 8.0 | 8.5 | 9.0 | 9.5 | 10.0 | 10.5 | 11.0 | 11.5 |
Hardness (HV) | 349.8 | 355.7 | 357.8 | 365.8 | 359.0 | 349.0 | 345.0 | 360.2 | 357.1 | 348.8 | 339.9 | 345.7 |
Distance (mm) | 0 | 0.25 | 0.5 | 0.75 | 1.0 | 1.25 | 1.5 | 1.75 | 2.0 | 2.25 | 2.5 |
---|---|---|---|---|---|---|---|---|---|---|---|
Hardness (HV) | 392.9 | 398.8 | 394.7 | 394.6 | 364.8 | 342.0 | 351.9 | 337.9 | 344.0 | 339.8 | 342.9 |
Distance (mm) | 2.75 | 3.0 | 3.25 | 3.5 | 3.75 | 4.0 | 4.35 | 4.5 | 4.75 | 5.0 | |
Hardness (HV) | 343.9 | 337.6 | 343.9 | 343.9 | 343.9 | 349.9 | 340.1 | 348.7 | 338.6 | 339.9 |
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Li, Y.; Hou, J.-Y.; Zheng, W.-J.; Wan, Z.-Q.; Tang, W.-Y. A Numerical Simulation Method Considering Solid Phase Transformation and the Experimental Verification of Ti6Al4V Titanium Alloy Sheet Welding Processes. Materials 2022, 15, 2882. https://doi.org/10.3390/ma15082882
Li Y, Hou J-Y, Zheng W-J, Wan Z-Q, Tang W-Y. A Numerical Simulation Method Considering Solid Phase Transformation and the Experimental Verification of Ti6Al4V Titanium Alloy Sheet Welding Processes. Materials. 2022; 15(8):2882. https://doi.org/10.3390/ma15082882
Chicago/Turabian StyleLi, Yu, Jia-Yi Hou, Wen-Jian Zheng, Zheng-Quan Wan, and Wen-Yong Tang. 2022. "A Numerical Simulation Method Considering Solid Phase Transformation and the Experimental Verification of Ti6Al4V Titanium Alloy Sheet Welding Processes" Materials 15, no. 8: 2882. https://doi.org/10.3390/ma15082882