Strength, fatigue strength and toughness of dissimilar Ti17-Ti64 linear friction welded joints: Effect of soft surface contamination and depletion of α precipitates

The effect of microstructure of three dissimilar Ti17-Ti64 linear friction welded joints on the strength, fatigue strength and fracture toughness was studied. A special attention was paid to role of soft contaminants and alpha precipitate depletion. Three joints were produced: one in the as machined state after electrical discharge machining, one ground prior to welding, and one welded in the as machined state and post-weld heat treated. The microstructure of the weld centre zone (WCZ) exhibited an acicular entangled alpha' martensite with a Wid-mansta center dot tten morphology on the Ti64 side and fine equiaxed distorted beta grains on the Ti17 side. A depletion of the strengthening alpha precipitates was observed in the WCZ and the thermo-mechanically affected zone (TMAZ) on the Ti17 side. For the studied welding parameters, the LFW self-cleaning mechanism failed to extrude the contaminants in the weld interface of the joint welded in the as machined state. These contaminants were related to prior to welding machining and were denominated soft contaminants due to their relatively low melting point. A defect layer was formed that led to a pseudo-brittle fracture in at the WCZ during tensile testing, cyclic loading and fracture toughness testing. During tensile testing of the joint that was ground prior to welding, failure occurred after plastic deformation sometimes at the Ti64 parent material (PM) and sometimes at the Ti17 TMAZ. Fatigue cracks initiated at the latter weak zone with a reduced fatigue strength. Compared to the PM, fracture toughness of samples even without fatigue pre-crack was also reduced. Failure at the weak zone highlighted unexpected colonies of elongated dimples that nucleated on transgranular deformation lines.