A Study On The Sustainable Machining of Titanium Alloy

05/09/2018 (PDF) Laser-TIG Welding of Titanium Alloys
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Laser-TIG Welding of Titanium Alloys
Article (PDF Available) · August 2016 with 136 Reads

DOI: 10.1088/1757-899X/142/1/012009
Cite this publication
G. A. Turichin
I Tsibulsky
19.09 · Peter the Great St.Petersburg Polytechnic University
Владислав Валерьевич Сомонов +1

7.3 · Peter the Great St.Petersburg Polyt...
Aleksandr Akhmetov
2.82 · Peter the Great St.Petersburg Polytechnic University
Show more authors
Abstract
The article presents the results of investigation the technological opportunity of laser-TIG welding of titanium alloys. The experimental stand
for implementation of process with the capability to feed a ller wire was made. The research of the nature of transfer the ller wire into the
welding pool has been demonstrated. The in uence of distance between the electrode and the surface of the welded plates on the stability of
the arc was shown. The relationship between welding velocity, the position of focal plane of the laser beam and the stability of penetration of
plates was determined.
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Microstructure of the joint weld
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VII International Scientiﬁc Practical Conference "Innovative Technologies in Engineering" IOP Publishing
IOP Conf. Series: Materials Science and Engineering 142 (2016) 012009 doi:10.1088/1757-899X/142/1/012009
G Turichin, I Tsibulsky, V Somonov1, M Kuznetsov, A Akhmetov
Peter the Great St.Petersburg Polytechnic University

195251, St. Petersburg, Politechnicheskya st, 29, ph. number (812)5529843
1
e-mail: vlad@ltc.ru
Abstract. The article presents the results of investigation the technological opportunity of
laser-TIG welding of titanium alloys. The experimental stand for implementation of process
with the capability to feed a filler wire was made. The research of the nature of transfer the
filler wire into the welding pool has been demonstrated. The influence of distance between the
electrode and the surface of the welded plates on the stability of the arc was shown. The
relationship between welding velocity, the position of focal plane of the laser beam and the
stability of penetration of plates was determined.
1. Introduction
Titanium and its alloys are indispensable construction materials because they have unique physical
properties: high specific strength comparable to steel. However, they have a density in two times less
than steels. The titanium alloys have a high melting point and corrosion resistance in aggressive
chemical environments, atmosphere and water.
Technology of welding titanium has the distinctive features. The titanium interacts actively with
atmospheric gases, such as oxygen, hydrogen, nitrogen during the heating more than 3500C; because
of this, the mechanical properties of joint weld significantly decrease. Titanium alloys are sensitive to
thermal cycle due to a heavy increase of grains during heating and cooling in the area of β phase.
Therefore, the welding should be done in the atmosphere of inert gas with minimum heat input. For
the formation of joint weld from titanium and its alloys in the world practice using various welding
methods: TIG welding, friction welding, electron beam welding. However, each of these methods has
its own significant imperfection. TIG welding have a low productivity. The friction welding has a
narrow field of application, as the dimensions of the welding parts are limited. The electron beam
welding has a limitation on the overall dimensions of the weld workpieces and it is a labour intensive
process due to there is the necessity of creating a vacuum in the working chamber. The welding of
titanium by laser radiation is the most promising. Analysis of the articles of other researchers revealed
a wide range of researches in this direction. There are researches with using of laser radiation of solid-
state laser in a pulse mode [1], with the aim of reducing residual welding deformations, and in
continuous mode for welding thick sheets of titanium (16mm) [2]. In addition, there are researches
with using of laser radiation of CO2 laser. Separate work are devoted to the description of results of the
research of laser welding with filler wire [3, 4], other about laser welding of titanium sheets overlap
research of laser welding with filler wire [3, 4], other about laser welding of titanium sheets overlap
See all › [5].
See all › However,
See the
all › most advantageous welding process of titanium alloy is laser-arc welding. The main
2 Citations advantages 1are
14 References Figure minimal welding deformation (comparable to the deformations formed at laser
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
Published under licence by IOP Publishing Ltd 1

welding), high welding speed, high depth of penetration, the capability of welding with gap, and the
capability of varying the chemical composition of the weld metal [6-8].
The aim of this work was to evaluate the technological opportunity of laser-TIG welding (LTW) of
titanium alloys Ti-1.5Al-1.0Mn and Ti-6Al-4V with a thickness of 5 mm.
Researches in this area are mainly represented with using of electron-beam welding, but also there
is the interest to the use of laser welding by a CO2 laser [9, 10] or solid-state laser [11].
The influence of the parameters of LTW on the formation of the joint weld was investigated during
research; also, the analysis of the microstructure and mechanical properties of joint weld was
produced.
2. The experimental researches

2.1. Welding equipment
The experimental researches of laser -TIG welding have been carried out with using a laser-arc
technological complex with fiber ytterbium laser LS-5 (IPG). It works in continuous mode and has
wavelength of radiation of 1070 nm and maximum output power of 5 kW.
The laser beam has been focused with a focal length of 300 mm in a spot with a diameter of 200
microns. The TIG welding source AC/DC TRITON 220 AC/DC Power Sinus (EWM) with the
maximum welding current and floating voltage 220A and 45V, respectively, has been used as arc
source. The feeder PDGO-601 («ITW») got the filler wire.
2.2. Welding materials
Plates from titanium alloys grade Ti-1.5Al-1.0Mn и Ti-6Al-4V with dimensions 200х400х5 mm
were used in the experiments. The welding wire Ti-1.5Al-1.0Mn with a diameter of 1.6 mm has been
used as the filler wire.
Chemical composition of titanium alloys are presented in table 1.
Table 1 - Chemical composition of titanium alloys
Fe C Si Mn V N Ti Al Zr O H others
Ti-
1.5Al- < 0.3 <0.1 < 0.15 0.7 - 2 < 0.05 94.138 - 98.3 1 - 2.5 < 0.3 < 0.15 < 0.012 0.3
1.0Mn
Ti-6Al- 3.5 -
< 0.3 < 0.1 < 0.15 < 0.05 86.485 - 91.2 5.3 - 6.8 < 0.3 < 0.2 < 0.015 0.3
4V 5.3

The argon and helium have been used as shielding gases for prevention of oxidation of the welding
pool and metal, heated to a temperature more than 3500C
2.3. Methods of quality control of the welds, test methods, test equipment
All welds have been subjected to visual inspection for existence of defects. For further study of
geometry, internal defects and microstructure of joint weld were made microsections. Researches of
the nature of transfer the filler wire into the welding pool and stability of the arc have been carried by
high-speed video camera CENTURIO C100, with the video frequency of 3000 frames/sec.
3. Experimental results and discussions

LTW have been carried in a lower position in one pass. The process is performed with maximum
output power of laser radiation of 5 kW for getting maximize productivity.

3.1 Melting of a filler wire

During the LTW process filler wire was applied along the seam from the side of the arc at the
smallest possible angle relative to the surface plate 10-150, figure 1.
Vweld
Figure 1 – Scheme of location of sources of heat and filler wire in LTW
For researches of the nature of melting of filler material was used a high-speed video. The frames
of high-speed video are shown in figure 2.

a b c d e
Figure 2 – Transferring of filler material in the welding pool: laser output power (PL) - 5kW,
velocity of LTW (Vweld) - 0.9 m/min, current of arc (I) - 140A, arc voltage (Uarc) to 18V, filler wire
feed speed (Vwire) - 1.1 m/min; the distance from the end of the electrode to the surface of the sheet (h)
- 3 mm.
As can be seen from figure 2, the process of melting the filler wire can be divided into several
stages. The heating of wire in front of by the arc and melting with the formation at the expense of
forces of surface tension of a spherical droplet at its end is shown in figure 2a. The growth of a
spherical droplet due to the melting of new portions of the filler wire and hold it on the end of the wire
due to the forces of surface tension are shown in figure 2b. The amount of molten metal filler wire and
the mass of droplet increase and due to the action of gravity, the drop changes its shape (figure 2c).
The drop is stretched out (figure 2d) and is separated from the end of filler wire and flowing into the
welding pool (figure 2e) when it approaches to the weld pool and increasing the pressure of the arc on
the surface.
The cyclical nature of this process provides a uniform transfer of molten filler metal to the welding
pool. The melting of the filler wire by arc component of LTW helps to use of costly laser radiation on
the penetration of the plates. Arc also provides pre-heating of the plates, increasing their absorption of
laser radiation.
3.2. The influence of the distance between the electrode and the surface of the welded plates on the
stability of arcing
LTW has been carried with the distance between the electrode and the surface of the plates in the
range from 2 to 3 mm. It helps to determine the optimal location of the electrode. The process of LTW

has been recorded by high-speed video camera. The frames of high-speed video are presented in figure
3.

a b
Figure 3 – Influence the distance between the electrode and the surface of the plates h on the stability
of arcing: a – h=2 mm, b – h=3 mm, (PL=5kW, Vweld=0.9 m/min, I=140A, Uarc=18V, Vwire=1.1
m/min)
According to the results of experimental studies of the nature of melting of filler wire (figure 2) the
melt droplet during its growth increases in volume with keeping a spherical shape. At some point of
time the diameter of the spherical drop is increased to 2 mm, sufficient for the circuits of the arc gap
(figure 3a). At the time of short circuit the arc goes out. The shape of drops changes because size of
drops, its mass increase, and the pressure of arc on the surface also increase. Thus, the melt droplet at
the end of filler wire has not time to reach a diameter of 3 mm and flows into the molten pool via the
mechanism described in the previous section (figure 3b), because of this, a short circuit is not formed,
and the arc burns steadily.
3.3. The influence of welding speed on the formation of a welded joint

The investigation of the influence of speed of LTW on the formation of a joint weld has been
performed in the range of 0.72 to 1.5 m/min. The electrode was positioned at a 300 angle from the
vertical. The distance between the axis of the laser radiation and the electrode on the surface of the
plates was 3 mm. LTW has been carried without filler wire and without the protection of the weld
root. The top side of the welding pool and the weld metal were protected by argon with flow rate of 30
l/min. The welding has been carried out at the following mode settings: laser power: 5 kW, embedding
of the focal plane of laser beam is 1 mm, the power arc current: 160A, arc voltage: 18V. The
appearance of the result of the experiment with stable full-penetration of plates are presented in figure
4.
Front side Backside
Figure 4 – The appearance of joint weld performed at LTW with welding velocity Vweld = 0.72 m/min
The results of welding performed at high speeds and, consequently, low heat input had not
stable full penetration. The joint weld formed at a velocity of 0.72 m/min and the maximum welding
heat input had the highest stability of full penetration. The results of this study it was decided to
perform further experiments of LTW at a welding velocity of 0.72 m/min.


2 Citations 3.4. The
14 References influence
1 Figure of deepening the focal plane of laser radiation on the formation of a joint weld
LTW with an embedding of focal plane Δf from 1 to 7 mm relative to the surface of the plates
has been performed with the aim of getting a stable full penetration. The welding has been carried out
on selected in the previous sub-section velocity with the same values of the other parameters of the
mode.
The welding process was carried out without filler wire and without the protection of the weld
root. The electrode was positioned at a 300 angle from the vertical. The distance between the axis of
the laser radiation and the electrode on the surface of the plates was 3 mm. The top side of the welding
pool and the weld metal were protected by argon with flow rate of 30 l/min. Appearance of joint weld
with stable penetration is presented in figure 5.
Front side Backside
a d
Figure 5 – Appearance of joint weld, Δf =1 mm
The top weld beads had annealing colours (Figure 5a). It shows about to the poor protection
during the welding process. Bottom weld beads had a rough surface and a brown color (Figure 5b). It
shows about the absence of protection of the weld metal. The reduction of the width of the bottom
weld bead and increase the width of the top weld bead at the embedding of the focal plane of the laser
beam was found during of visually control of geometry of joint weld.
The stable formation of a bottom weld bead (full penetration) was detected at the deepening of
the focal plane relative to the top surface of the plate by 1 mm.
Then LTW with the filler wire was performed. The mode of parameters are presented in table 2.
The welding pool and the metal is heated to a temperature above 3500C were protected by argon. The
appearance of welded joints is presented in figure 6.
Table 2 – The mode of parameters of LTW

№ PL, kW Vweld, m/min Δf, mm I, А Uarc , V
8 5 0.72 -1 160 18
Front side Backside
Figure 6 – Appearance of joint weld with filler wire
Any visual defects have been not detected by visual control of joint weld. The joint weld had a
stable full penetration. The colour of top weld bead changed from light silver to light straw. The
bottom weld bead had a light silver color. It indicates about a uniform quality protection.
3. Metallographic tests
During visual control of the cross section of a joint weld by optical microscope, the increase in the
width of weld in the upper and lower parts has been found. The main contribution to end-to-end


penetration introduces laser radiation; the energy of the arc is used for melting the filler material and
the upper layers of the plate.
3.1. The microstructure of the joint weld

The titanium alloys investigated in this work belong to different groups: Ti-1.5Al-1.0Mn - pseudo-
α alloy containing β phase and Ti-6Al-4V – the alloy of the martensitic type, similar to the pseudo α
alloy.
The alloys Ti-1.5Al-1.0Mn and Ti-6Al-4V have been welded between each other with application
of welding wire with a chemical composition corresponding to Ti-1.5Al-1.0Mn and the resulting
structure of the weld metal composed of martensite α’ – phase.
Three characteristic areas were found in the HAZ of the joint weld:
the area with big size of grains (overheating), where the temperature varies from the melting
temperature to 1300°C;
the area with full recrystallization, where upon cooling, the structures are similar to those that occur
at the area with big size of grains;
the area of incomplete recrystallization (figure 7).
Figure 7 – Microstructure of the joint weld
4. Mechanical tests
4.1. Static tension
From the weld joint were manufactured samples for tests on static stretching according to
GOST 1497-84 "Methods of tensile tests". According to test results, the value of temporary resistance
ranged from 653 to 661 MPa, and the fracture of specimen occurred in the base metal. This proves that
the parameters of the mode of LTW provide a generation a joint weld with the strength simillar to base
metal
metal.

4.2. The microhardness tests
The microhardness tests have been carried out according to the scheme presented in figure 8.
Figure 8 - Scheme of microhardness measurement.
The results of measurement of microhardness are presented in table 3.
Table 3 – The results of measurement of microhardness
№ 1 2 3 4 5 6 7 8
283.3 282.9 253.9 272 231.1 272.4 273.8 264.4
HV
9 10 11 12 13
211 213.2 264.6 247.9 214.2
The weld seam had a hardness middle between Ti-6Al-4V (numbers 1, 6, 11) and Ti-1.5Al-
1.0Mn (numbers 5, 10, 13) about 260 HV.
The study of the chemical composition of the weld metal detected that it is formed of filler
y p
material Ti-1.5 Al-1.0Mn. The presence of V is not detected in the composition of the weld metal. It
indicates about a minimum amount of Ti-6Al-4V in the composition of the weld metal.
Conclusion
During the research, the nature of transport of metal filler wire into the weld pool has been
investigated. The melting of it in front of the weld pool by arc with a uniform drop transport
mechanism has been detected. The minimal distance between the end electrode and the surface of the
welded plates, providing steady-state combustion of arc is 3 mm. The devices providing reliable
protection of the molten metal and metal heated over a temperature of 3500C, from the atmosphere
have been made. The relationship between welding velocity, the position of focal plane of the laser
beam and the stability of penetration of plates was determined.

According to the results of research the technology laser-TIG welding with the filler wire of
titanium alloys Ti-1.5Al-1.0 Mn and Ti-6Al-4V with a thickness of 5 mm has been developed. The
welded joints with satisfactory mechanical properties were obtained.
References
[1] K. Richter, W. Behr, U. Reisgen, 2007, Low Heat Welding of Titanium Materials with a Pulsed
Nd:YAG Laser, Materialwissenschaft und Werkstofftechnik, Volume 38, Issue 1, pp 51–56.
[2] Andre Schneider, Andrey Gumenyuk, Marco Lammers, Andreas Malletschek, Michael
Rethmeier, 2014, Laser beam welding of thick titanium sheets in the field of marine
technology, Physics Procedia 56 ( 2014 ), pp 582 – 590.
[3] Nikolai Kashaev, Volker Ventzke, Manfred Horstmann, Stefan Riekehr, Grigory Yashin,
Lennart Stutz, Werner Beck, 2014, Microstructure and Mechanical Properties of Laser Beam
Welded Joints between Fine-Grained and Standard Ti-6Al-4V Sheets Subjected to
Superplastic Forming, Advanced Engineering Materials, 2015, 17, No. 3, pp 374-382.
[4] Bergmann, J.P., 2005, Mechanical behaviour of overlap joints of titanium, Science and
Technology of Welding and Joining, Volume 10, Issue 1, February 2005, pp 50-60.
[5] Liu L.M., Hao X.F., Du X., 2008, Microstructure characteristics and mechanical properties of
laser-TIG hybrid welding joint of TA15 titanium alloy, Materials Research Innovations,
Volume 12, Issue 3, September 2008, pp 114-118.
[6] Turichin, G. , Velichko, O., Kuznetsov, A., Pevzner, J., Grinin, O., Kuznetsov, M., 2014,
Design of mobile hybrid laser-arc welding system on the base of 20 kW fiber laser,
Proceedings - 2014 International Conference Laser Optics, LO 2014.
[7] Tsibulskiy, I., Kuznetsov, M., Akhmetov, A. Effect of welding position and gap between
samples on hybrid laser-arc welding efficiency, Applied Mechanics and Materials, Volume
682, 2014, pp 35-40.
[8] Wang S.Q., Liu J.H., Chen D.L. 2013, Strain-controlled fatigue properties of dissimilar welded
g g p p
joints between Ti–6Al–4V and Ti17 alloys, Materials and Design, Volume 49, pp 716–727.
2 Citations [9] Liu P.
14 References S., Baeslack III W. A., Hurley J. 1994, Dissimilar Alloy Laser Beam Welding of
1 Figure
Titanium: Ti-6AI-4V to Beta-C™, Welding Research Supplement, pp 175–181.
[10] Chiu C.Y., Lu M.Y., Tsay L.W., 2011, Dissimilar laser welding of Ti-6Al-4V to Ti-6Al-6V-
2Sn, Advanced Materials Research, Volume 295-297, pp 2353-2357.
[11] Chiu C.Y., Hsieh C.T., Tsay L.W., 2014, Microstructure and notched tensile fracture of Ti–
6Al–4V to Ti–4.5Al–3V–2Fe–2Mo dissimilar welds, Materials and Design, Volume 63, pp
14–19.

Citations (2) References (14)
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the weld is higher than that of the TA15 alloy [15]. ...
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05/09/2018 (PDF) Laser-TIG Welding of Titanium Alloys

Laser-TIG Welding of Titanium Alloys

Article (PDF Available) · August 2016 with 136 Reads

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Владислав Валерьевич Сомонов +1

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Microstructure of the joint weld

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Laser-TIG Welding of Titanium Alloys

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Laser-TIG Welding of Titanium Alloys

G Turichin, I Tsibulsky, V Somonov1, M Kuznetsov, A Akhmetov

Peter the Great St.Petersburg Polytechnic University

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2. The experimental researches

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3. Experimental results and discussions

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3.1 Melting of a filler wire

Figure 1 – Scheme of location of sources of heat and filler wire in LTW

See all › See all › See all ›

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3.3. The influence of welding speed on the formation of a welded joint

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Front side Backside

Figure 5 – Appearance of joint weld, Δf =1 mm

Table 2 – The mode of parameters of LTW

Front side Backside

Figure 6 – Appearance of joint weld with filler wire

See all › See all › See all ›

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3.1. The microstructure of the joint weld

Figure 7 – Microstructure of the joint weld

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4.2. The microhardness tests

Figure 8 - Scheme of microhardness measurement.

The results of measurement of microhardness are presented in table 3.

Table 3 – The results of measurement of microhardness

283.3 282.9 253.9 272 231.1 272.4 273.8 264.4

211 213.2 264.6 247.9 214.2

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Investigation of the in uence of ultrasonic waves on the microstructure on laser welds

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