Overview of Welding and Joining of Titanium

Copyright TWI Ltd 2009World Centre for Materials Joining TechnologyWorld Centre for Materials Joining TechnologyWorld Centre for Materials Joining TechnologyWorld Centre for Materials Joining Technology

Overview of welding and joining Overview of welding and joining Overview of welding and joining Overview of welding and joining Overview of welding and joining Overview of welding and joining Overview of welding and joining Overview of welding and joining of titaniumof titaniumof titaniumof titaniumof titaniumof titaniumof titaniumof titanium

Dr. Richard Freeman Dr. Richard Freeman Dr. Richard Freeman Dr. Richard Freeman Dr. Richard Freeman Dr. Richard Freeman Dr. Richard Freeman Dr. Richard Freeman TWI Ltd, TWI Ltd, TWI Ltd, TWI Ltd, TWI Ltd, TWI Ltd, TWI Ltd, TWI Ltd, Cambridge, UKCambridge, UKCambridge, UKCambridge, UKCambridge, UKCambridge, UKCambridge, UKCambridge, UKEuropean Titanium Conference 23European Titanium Conference 23European Titanium Conference 23European Titanium Conference 23European Titanium Conference 23European Titanium Conference 23European Titanium Conference 23European Titanium Conference 23--------24 24 24 24 24 24 24 24 June 2009June 2009June 2009June 2009June 2009June 2009June 2009June 2009


AgendaAgendaAgendaAgendaAgendaAgendaAgendaAgenda Brief introduction to TWIBrief introduction to TWIBrief introduction to TWIBrief introduction to TWIBrief introduction to TWIBrief introduction to TWIBrief introduction to TWIBrief introduction to TWI Welding and joining of TiWelding and joining of TiWelding and joining of TiWelding and joining of TiWelding and joining of TiWelding and joining of TiWelding and joining of TiWelding and joining of Ti Arc welding developmentsArc welding developmentsArc welding developmentsArc welding developmentsArc welding developmentsArc welding developmentsArc welding developmentsArc welding developments Friction welding developmentsFriction welding developmentsFriction welding developmentsFriction welding developmentsFriction welding developmentsFriction welding developmentsFriction welding developmentsFriction welding developments SummarySummarySummarySummarySummarySummarySummarySummary


What is TWI ?What is TWI ?What is TWI ?What is TWI ?What is TWI ?What is TWI ?What is TWI ?What is TWI ?

Membership based Membership based Membership based Membership based Membership based Membership based Membership based Membership based Research and Technology Research and Technology Research and Technology Research and Technology Research and Technology Research and Technology Research and Technology Research and Technology OrganisationOrganisationOrganisationOrganisationOrganisationOrganisationOrganisationOrganisation since 1946since 1946since 1946since 1946since 1946since 1946since 1946since 1946

Professional society Professional society Professional society Professional society Professional society Professional society Professional society Professional society Company limited by Company limited by Company limited by Company limited by Company limited by Company limited by Company limited by Company limited by

guaranteeguaranteeguaranteeguaranteeguaranteeguaranteeguaranteeguarantee 550 staff worldwide550 staff worldwide550 staff worldwide550 staff worldwide550 staff worldwide550 staff worldwide550 staff worldwide550 staff worldwide 45m 45m 45m 45m 45m 45m 45m 45m turnover in 2008turnover in 2008turnover in 2008turnover in 2008turnover in 2008turnover in 2008turnover in 2008turnover in 2008 Over 3500 Industrial Over 3500 Industrial Over 3500 Industrial Over 3500 Industrial Over 3500 Industrial Over 3500 Industrial Over 3500 Industrial Over 3500 Industrial

members in 60 countriesmembers in 60 countriesmembers in 60 countriesmembers in 60 countriesmembers in 60 countriesmembers in 60 countriesmembers in 60 countriesmembers in 60 countries Non profit distributingNon profit distributingNon profit distributingNon profit distributingNon profit distributingNon profit distributingNon profit distributingNon profit distributing

World Centre for Materials Joining TechnologyWorld Centre for Materials Joining TechnologyWorld Centre for Materials Joining TechnologyWorld Centre for Materials Joining TechnologyWorld Centre for Materials Joining TechnologyWorld Centre for Materials Joining TechnologyWorld Centre for Materials Joining TechnologyWorld Centre for Materials Joining Technology


Welding & Joining of TiWelding & Joining of TiWelding & Joining of TiWelding & Joining of TiWelding & Joining of TiWelding & Joining of TiWelding & Joining of TiWelding & Joining of Ti Arc weldingArc weldingArc weldingArc weldingArc weldingArc weldingArc weldingArc welding Laser welding and Laser welding and Laser welding and Laser welding and Laser welding and Laser welding and Laser welding and Laser welding and direct metal depositiondirect metal depositiondirect metal depositiondirect metal depositiondirect metal depositiondirect metal depositiondirect metal depositiondirect metal deposition Electron beam welding and surface texturingElectron beam welding and surface texturingElectron beam welding and surface texturingElectron beam welding and surface texturingElectron beam welding and surface texturingElectron beam welding and surface texturingElectron beam welding and surface texturingElectron beam welding and surface texturing Friction weldingFriction weldingFriction weldingFriction weldingFriction weldingFriction weldingFriction weldingFriction welding Diffusion bondingDiffusion bondingDiffusion bondingDiffusion bondingDiffusion bondingDiffusion bondingDiffusion bondingDiffusion bonding Brazing and solderingBrazing and solderingBrazing and solderingBrazing and solderingBrazing and solderingBrazing and solderingBrazing and solderingBrazing and soldering


Arc WeldingArc WeldingArc WeldingArc WeldingArc WeldingArc WeldingArc WeldingArc WeldingHF DCEN TIGHF DCEN TIGHF DCEN TIGHF DCEN TIGHF DCEN TIGHF DCEN TIGHF DCEN TIGHF DCEN TIG

TOPTIGTOPTIGTOPTIGTOPTIGTOPTIGTOPTIGTOPTIGTOPTIGKeyhole PlasmaKeyhole PlasmaKeyhole PlasmaKeyhole PlasmaKeyhole PlasmaKeyhole PlasmaKeyhole PlasmaKeyhole Plasma

Reduced Spatter MIGReduced Spatter MIGReduced Spatter MIGReduced Spatter MIGReduced Spatter MIGReduced Spatter MIGReduced Spatter MIGReduced Spatter MIG


High frequency TIG weldingHigh frequency TIG weldingHigh frequency TIG weldingHigh frequency TIG weldingHigh frequency TIG weldingHigh frequency TIG weldingHigh frequency TIG weldingHigh frequency TIG welding

INTERPULSE

WELD DEPOSIT

INVERTER

WELD DEPOSIT


TOPTIGTOPTIGTOPTIGTOPTIGTOPTIGTOPTIGTOPTIGTOPTIG TOPTIG claims :TOPTIG claims :

High quality / No High quality / No spatterspatter

Good welding speed Good welding speed (MIG)(MIG)

Reasonable Reasonable Investment CostsInvestment Costs

MIG Welding TOPTIG

Courtesy Air Liquide CTAS


Keyhole Plasma WeldingKeyhole Plasma WeldingKeyhole Plasma WeldingKeyhole Plasma WeldingKeyhole Plasma WeldingKeyhole Plasma WeldingKeyhole Plasma WeldingKeyhole Plasma Welding Higher productivity than TIG Higher productivity than TIG Higher productivity than TIG Higher productivity than TIG Higher productivity than TIG Higher productivity than TIG Higher productivity than TIG Higher productivity than TIG and MIGand MIGand MIGand MIGand MIGand MIGand MIGand MIG Deep penetration in single Deep penetration in single Deep penetration in single Deep penetration in single Deep penetration in single Deep penetration in single Deep penetration in single Deep penetration in single pass pass pass pass pass pass pass pass -------- up to 18mm up to 18mm up to 18mm up to 18mm up to 18mm up to 18mm up to 18mm up to 18mm Above 4mm, welding speed Above 4mm, welding speed Above 4mm, welding speed Above 4mm, welding speed Above 4mm, welding speed Above 4mm, welding speed Above 4mm, welding speed Above 4mm, welding speed is typically 3 times that of is typically 3 times that of is typically 3 times that of is typically 3 times that of is typically 3 times that of is typically 3 times that of is typically 3 times that of is typically 3 times that of conventional TIGconventional TIGconventional TIGconventional TIGconventional TIGconventional TIGconventional TIGconventional TIG Reduced susceptibility to Reduced susceptibility to Reduced susceptibility to Reduced susceptibility to Reduced susceptibility to Reduced susceptibility to Reduced susceptibility to Reduced susceptibility to porosityporosityporosityporosityporosityporosityporosityporosity


Plasma keyhole weld jointsPlasma keyhole weld jointsPlasma keyhole weld jointsPlasma keyhole weld jointsPlasma keyhole weld jointsPlasma keyhole weld jointsPlasma keyhole weld jointsPlasma keyhole weld joints Square edge closed Square edge closed Square edge closed Square edge closed Square edge closed Square edge closed Square edge closed Square edge closed

butt in 10 mm Ti6246butt in 10 mm Ti6246butt in 10 mm Ti6246butt in 10 mm Ti6246butt in 10 mm Ti6246butt in 10 mm Ti6246butt in 10 mm Ti6246butt in 10 mm Ti6246 Single Single Single Single Single Single Single Single autogenousautogenousautogenousautogenousautogenousautogenousautogenousautogenous weld weld weld weld weld weld weld weld

pass with 200mm/min pass with 200mm/min pass with 200mm/min pass with 200mm/min pass with 200mm/min pass with 200mm/min pass with 200mm/min pass with 200mm/min welding speedwelding speedwelding speedwelding speedwelding speedwelding speedwelding speedwelding speed

Edge joint in 10mm Edge joint in 10mm Edge joint in 10mm Edge joint in 10mm Edge joint in 10mm Edge joint in 10mm Edge joint in 10mm Edge joint in 10mm thick Tithick Tithick Tithick Tithick Tithick Tithick Tithick Ti--------62466246624662466246624662466246


Conventional wireG-coat wire (WT2G)

MIG welding using different wiresMIG welding using different wiresMIG welding using different wiresMIG welding using different wiresMIG welding using different wiresMIG welding using different wiresMIG welding using different wiresMIG welding using different wires

Welding Wire : Titanium (ErTiWelding Wire : Titanium (ErTi--2) ; 1.0mm2) ; 1.0mm

Welding Condition : 100AWelding Condition : 100A--17V17V--60cm/min 60cm/min


BeadBeadBeadBeadBeadBeadBeadBead--------onononononononon--------PlatePlatePlatePlatePlatePlatePlatePlate

Novel wire(G-Coat) - Argon shield

Conventional wire (CP-Ti) - Argon shield

30mm

30mm


Laser Direct Metal DepositionLaser Direct Metal DepositionLaser Direct Metal DepositionLaser Direct Metal DepositionLaser Direct Metal DepositionLaser Direct Metal DepositionLaser Direct Metal DepositionLaser Direct Metal Deposition


Laser DMD Laser DMD Laser DMD Laser DMD Laser DMD Laser DMD Laser DMD Laser DMD

Laser beam is focussed onto a substrate to Laser beam is focussed onto a substrate to Laser beam is focussed onto a substrate to Laser beam is focussed onto a substrate to Laser beam is focussed onto a substrate to Laser beam is focussed onto a substrate to Laser beam is focussed onto a substrate to Laser beam is focussed onto a substrate to create a molten pool into which a powder is create a molten pool into which a powder is create a molten pool into which a powder is create a molten pool into which a powder is create a molten pool into which a powder is create a molten pool into which a powder is create a molten pool into which a powder is create a molten pool into which a powder is delivered by a carrier gasdelivered by a carrier gasdelivered by a carrier gasdelivered by a carrier gasdelivered by a carrier gasdelivered by a carrier gasdelivered by a carrier gasdelivered by a carrier gas

Powder is melted onto substrate to form a Powder is melted onto substrate to form a Powder is melted onto substrate to form a Powder is melted onto substrate to form a Powder is melted onto substrate to form a Powder is melted onto substrate to form a Powder is melted onto substrate to form a Powder is melted onto substrate to form a solidified layer of materialsolidified layer of materialsolidified layer of materialsolidified layer of materialsolidified layer of materialsolidified layer of materialsolidified layer of materialsolidified layer of material


Deposition NozzleDeposition NozzleDeposition NozzleDeposition NozzleDeposition NozzleDeposition NozzleDeposition NozzleDeposition Nozzle

Tighter powder focusTighter powder focusTighter powder focusTighter powder focusTighter powder focusTighter powder focusTighter powder focusTighter powder focus Better powder efficiencyBetter powder efficiencyBetter powder efficiencyBetter powder efficiencyBetter powder efficiencyBetter powder efficiencyBetter powder efficiencyBetter powder efficiency Reduced material wasteReduced material wasteReduced material wasteReduced material wasteReduced material wasteReduced material wasteReduced material wasteReduced material waste Good localised Good localised Good localised Good localised Good localised Good localised Good localised Good localised

shieldingshieldingshieldingshieldingshieldingshieldingshieldingshieldingNozzle

Nozzle gasWater circulation

Powder delivery


Ti Grading Ti Grading Ti Grading Ti Grading Ti Grading Ti Grading Ti Grading Ti Grading -------- MacrosMacrosMacrosMacrosMacrosMacrosMacrosMacros

Increasing Ti Increasing Ti Increasing Ti Increasing Ti Increasing Ti Increasing Ti Increasing Ti Increasing Ti --------62426242624262426242624262426242


DemonstratorDemonstratorDemonstratorDemonstratorDemonstratorDemonstratorDemonstratorDemonstrator

Material graded from Material graded from Material graded from Material graded from Material graded from Material graded from Material graded from Material graded from

TiTiTiTiTiTiTiTi--------66666666--------4 to Ti 62424 to Ti 62424 to Ti 62424 to Ti 62424 to Ti 62424 to Ti 62424 to Ti 62424 to Ti 6242


Titanium 6Titanium 6Titanium 6Titanium 6Titanium 6Titanium 6Titanium 6Titanium 6--------4 4 4 4 4 4 4 4 in airin airin airin airin airin airin airin air DemonstratorDemonstratorDemonstratorDemonstratorDemonstratorDemonstratorDemonstratorDemonstrator

500mm500mm500mm500mm


Friction WeldingFriction WeldingFriction WeldingFriction WeldingFriction WeldingFriction WeldingFriction WeldingFriction WeldingFriction Stir WeldingFriction Stir WeldingFriction Stir WeldingFriction Stir WeldingFriction Stir WeldingFriction Stir WeldingFriction Stir WeldingFriction Stir Welding

Linear Friction WeldingLinear Friction WeldingLinear Friction WeldingLinear Friction WeldingLinear Friction WeldingLinear Friction WeldingLinear Friction WeldingLinear Friction Welding


Novel non-fusion welding process invented in 1991 by TWI Ltd.

Industrialised within 5 years.

Now licensed to 175 organisations world-wide.

Applications in marine, aerospace, automotive, rail, and construction.

Developed for Al, Mg, Cu, Zn, demonstrated in Steels, Ti, Ni.

Friction Stir WeldingFriction Stir WeldingFriction Stir WeldingFriction Stir WeldingFriction Stir WeldingFriction Stir WeldingFriction Stir WeldingFriction Stir Welding


Success of initial work led to formation of a TWI group sponsored project (GSP).

GSP ran from 1996 to 2001 to develop FSW for Ti alloys.

Trials conducted on 6.35mm ( inch) thickness Ti-6Al-4V.

A major challenge was found to be the generation of sufficient heat without causing over-softening of the weld material.

Surface overheating resulted in loss of weld containment.

Cold weld, poor root

Hot weld, poor surface

Development of FSW of TiDevelopment of FSW of TiDevelopment of FSW of TiDevelopment of FSW of TiDevelopment of FSW of TiDevelopment of FSW of TiDevelopment of FSW of TiDevelopment of FSW of Ti


The FSW probe rotates The FSW probe rotates through a stationary through a stationary shoulder/slide component.shoulder/slide component.

The nonThe non--rotating shoulder rotating shoulder component adds no heat component adds no heat to the weld surface.to the weld surface.

The resulting heat input The resulting heat input profile is basically linear.profile is basically linear.

This approach is of great This approach is of great help in the welding of low help in the welding of low conductivity materials.conductivity materials.Copyright 2006, TWI Ltd. Patent Pending

Stationary Shoulder ApproachStationary Shoulder ApproachStationary Shoulder ApproachStationary Shoulder ApproachStationary Shoulder ApproachStationary Shoulder ApproachStationary Shoulder ApproachStationary Shoulder ApproachNew approach developed by TWI:New approach developed by TWI:New approach developed by TWI:New approach developed by TWI:


Inert gas is pumped into the system, both around and behind the tool giving a very weld clean surface.

Stationary Shoulder ApproachStationary Shoulder ApproachStationary Shoulder ApproachStationary Shoulder ApproachStationary Shoulder ApproachStationary Shoulder ApproachStationary Shoulder ApproachStationary Shoulder Approach


Welds typically have an excellent surface finish and near parent mechanical properties:

SSFSW of Ti SSFSW of Ti SSFSW of Ti SSFSW of Ti SSFSW of Ti SSFSW of Ti SSFSW of Ti SSFSW of Ti -------- PropertiesPropertiesPropertiesPropertiesPropertiesPropertiesPropertiesProperties

6.35mm Ti-6Al-4V butt weld produced at 100mm/min2mm


FSW Additive Manufacture in TiFSW Additive Manufacture in TiFSW Additive Manufacture in TiFSW Additive Manufacture in TiFSW Additive Manufacture in TiFSW Additive Manufacture in TiFSW Additive Manufacture in TiFSW Additive Manufacture in TiProProProPro----StirStirStirStir Demonstration in a Ti alloy:Demonstration in a Ti alloy:Demonstration in a Ti alloy:Demonstration in a Ti alloy:

Lap welding of 4 sheets to build up a flange structure in Ti-6Al-4V


LinfricLinfricLinfricLinfricLinfricLinfricLinfricLinfric MachineMachineMachineMachineMachineMachineMachineMachine LFW machine LFW machine

fixtures/systems have been fixtures/systems have been developed using TWI developed using TWI exploratory funding and exploratory funding and some European project some European project funding.funding.

Improved process Improved process understanding has also been understanding has also been developed via exploratory developed via exploratory work, using work, using TWITWIss new high new high speed video system.speed video system.


100m

LFW Weld Quality in TiLFW Weld Quality in TiLFW Weld Quality in TiLFW Weld Quality in TiLFW Weld Quality in TiLFW Weld Quality in TiLFW Weld Quality in TiLFW Weld Quality in Ti--------6Al6Al6Al6Al6Al6Al6Al6Al--------4V4V4V4V4V4V4V4V

10mm

Fine grained hot forged weld microstructure

Recrystallised to fine grained equiaxed m/s at weld centre

Near parent tensile and fatigue properties can be achieved


LFW of LFW of LFW of LFW of BlisksBlisksBlisksBlisks for the for the for the for the EurofighterEurofighterEurofighterEurofighter Typhoon by MTU, MunichTyphoon by MTU, MunichTyphoon by MTU, MunichTyphoon by MTU, Munich

FFP Technology FFP Technology FFP Technology FFP Technology FFP Technology FFP Technology FFP Technology FFP Technology -------- LFWLFWLFWLFWLFWLFWLFWLFWLinear Friction Welding Applications Linear Friction Welding Applications Linear Friction Welding Applications Linear Friction Welding Applications Linear Friction Welding Applications Linear Friction Welding Applications Linear Friction Welding Applications Linear Friction Welding Applications -------- BlisksBlisksBlisksBlisksBlisksBlisksBlisksBlisks


Additive Manufacture of Ti Alloy Additive Manufacture of Ti Alloy Additive Manufacture of Ti Alloy Additive Manufacture of Ti Alloy PreformsPreformsPreformsPreforms by LFW:by LFW:by LFW:by LFW:Secondary WeldsSecondary WeldsInitial WeldsInitial Welds

Finish MachineFinish Machine Boeing Concept for Structural Assemblies and Machining Preforms formed by LFW

Pat. No. US2005127140 (The Boeing Company)

LFW of LFW of LFW of LFW of LFW of LFW of LFW of LFW of PreformsPreformsPreformsPreformsPreformsPreformsPreformsPreforms -------- ExamplesExamplesExamplesExamplesExamplesExamplesExamplesExamples


LFW of Machining LFW of Machining LFW of Machining LFW of Machining LFW of Machining LFW of Machining LFW of Machining LFW of Machining PreformsPreformsPreformsPreformsPreformsPreformsPreformsPreformsLFW of LFW of LFW of LFW of LFW of LFW of LFW of LFW of preformspreformspreformspreformspreformspreformspreformspreforms

Part Specification LFW Preform (part machined)

LFW of Preforms - demonstration work carried out in conjunction with Thompson Friction Welding.


SummarySummarySummarySummarySummarySummarySummarySummary TWI is involved in a multitude of welding and TWI is involved in a multitude of welding and TWI is involved in a multitude of welding and TWI is involved in a multitude of welding and TWI is involved in a multitude of welding and TWI is involved in a multitude of welding and TWI is involved in a multitude of welding and TWI is involved in a multitude of welding and

joining processes for its customer base in the joining processes for its customer base in the joining processes for its customer base in the joining processes for its customer base in the joining processes for its customer base in the joining processes for its customer base in the joining processes for its customer base in the joining processes for its customer base in the aerospace, defence and oil and gas aerospace, defence and oil and gas aerospace, defence and oil and gas aerospace, defence and oil and gas aerospace, defence and oil and gas aerospace, defence and oil and gas aerospace, defence and oil and gas aerospace, defence and oil and gas businessesbusinessesbusinessesbusinessesbusinessesbusinessesbusinessesbusinesses

Work in the welding and joining of Ti has Work in the welding and joining of Ti has Work in the welding and joining of Ti has Work in the welding and joining of Ti has Work in the welding and joining of Ti has Work in the welding and joining of Ti has Work in the welding and joining of Ti has Work in the welding and joining of Ti has trebled in the last 6 yearstrebled in the last 6 yearstrebled in the last 6 yearstrebled in the last 6 yearstrebled in the last 6 yearstrebled in the last 6 yearstrebled in the last 6 yearstrebled in the last 6 years

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Overview of Welding and Joining of Titanium