Analysis of microstructural evolution and mechanical properties of FGH101 powder superalloy and IN718 deformed superalloy via inertia friction welding
Nickel-based superalloys are indispensable in aerospace engines due to their exceptional high-temperature strength, oxidation resistance, and corrosion resistance, making them critical for joining processes such as inertia friction welding (IFW), which is favored for its efficiency and superior join...
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Frontiers Media S.A.
2025-01-01
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| Series: | Frontiers in Materials |
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| Online Access: | https://www.frontiersin.org/articles/10.3389/fmats.2024.1544584/full |
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| author | Jun Zhou Jun Zhou Yongqiang Zhang Yongqiang Zhang Yongqiang Zhang Feng Qin Feng Qin Xuelong Zhang Xuelong Zhang Hao Wang Hao Wang Ze Liu Ze Liu Wenhan Zhang Wenhan Zhang Caiyan Huang Caiyan Huang Chunbo Zhang Chunbo Zhang |
| author_facet | Jun Zhou Jun Zhou Yongqiang Zhang Yongqiang Zhang Yongqiang Zhang Feng Qin Feng Qin Xuelong Zhang Xuelong Zhang Hao Wang Hao Wang Ze Liu Ze Liu Wenhan Zhang Wenhan Zhang Caiyan Huang Caiyan Huang Chunbo Zhang Chunbo Zhang |
| author_sort | Jun Zhou |
| collection | DOAJ |
| description | Nickel-based superalloys are indispensable in aerospace engines due to their exceptional high-temperature strength, oxidation resistance, and corrosion resistance, making them critical for joining processes such as inertia friction welding (IFW), which is favored for its efficiency and superior joint quality. In this study, IFW was used to join FGH101 powder superalloy with IN718 deformed superalloy, resulting in significant plastic deformation that formed symmetrical ear-shaped flash on the IN718 side and minor upsetting on the FGH101 side, with a wavy interface due to heat dissipation. Microhardness analysis revealed higher hardness at the weld interface, followed by a sharp decline near the Heat Affected Zone (HAZ) on the IN718 side due to phase re-dissolution, while FGH101 showed quicker recovery. Post-weld aging treatments enhanced hardness and strength through γ′ and δ phase precipitation in FGH101 and γ″ phases in IN718. Room temperature tensile tests demonstrated impressive strength with failures occurring plastically within the IN718 base metal, whereas elevated temperatures shifted failure locations to the weld zone without necking. Fatigue tests exhibited varied lifespans, with fractures initiating either at stress concentrators or within the FGH101 base metal far from the weld center. Scanning electron microscope (SEM) analysis confirmed mixed-mode fracture patterns, underscoring the importance of microstructure on joint performance and suggesting that optimizing IFW parameters can lead to superior weld quality in aerospace components, thus providing valuable insights for future research and industrial applications. |
| format | Article |
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| institution | Kabale University |
| issn | 2296-8016 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | Frontiers Media S.A. |
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| series | Frontiers in Materials |
| spelling | doaj-art-b3438ca230ca481195d5e0b0e65dc1712025-01-30T14:12:41ZengFrontiers Media S.A.Frontiers in Materials2296-80162025-01-011110.3389/fmats.2024.15445841544584Analysis of microstructural evolution and mechanical properties of FGH101 powder superalloy and IN718 deformed superalloy via inertia friction weldingJun Zhou0Jun Zhou1Yongqiang Zhang2Yongqiang Zhang3Yongqiang Zhang4Feng Qin5Feng Qin6Xuelong Zhang7Xuelong Zhang8Hao Wang9Hao Wang10Ze Liu11Ze Liu12Wenhan Zhang13Wenhan Zhang14Caiyan Huang15Caiyan Huang16Chunbo Zhang17Chunbo Zhang18Harbin Welding Institute Limited Company, China Academy of Machinery, Harbin, ChinaHeilongjiang Key Laboratory of Advanced Friction Welding Technology and Equipment, Harbin, ChinaHarbin Welding Institute Limited Company, China Academy of Machinery, Harbin, ChinaHeilongjiang Key Laboratory of Advanced Friction Welding Technology and Equipment, Harbin, ChinaAECC Commercial Aircraft Engine Co., Ltd., Shanghai, ChinaHarbin Welding Institute Limited Company, China Academy of Machinery, Harbin, ChinaHeilongjiang Key Laboratory of Advanced Friction Welding Technology and Equipment, Harbin, ChinaHarbin Welding Institute Limited Company, China Academy of Machinery, Harbin, ChinaHeilongjiang Key Laboratory of Advanced Friction Welding Technology and Equipment, Harbin, ChinaHarbin Welding Institute Limited Company, China Academy of Machinery, Harbin, ChinaHeilongjiang Key Laboratory of Advanced Friction Welding Technology and Equipment, Harbin, ChinaHarbin Welding Institute Limited Company, China Academy of Machinery, Harbin, ChinaHeilongjiang Key Laboratory of Advanced Friction Welding Technology and Equipment, Harbin, ChinaHarbin Welding Institute Limited Company, China Academy of Machinery, Harbin, ChinaHeilongjiang Key Laboratory of Advanced Friction Welding Technology and Equipment, Harbin, ChinaHarbin Welding Institute Limited Company, China Academy of Machinery, Harbin, ChinaHeilongjiang Key Laboratory of Advanced Friction Welding Technology and Equipment, Harbin, ChinaHarbin Welding Institute Limited Company, China Academy of Machinery, Harbin, ChinaHeilongjiang Key Laboratory of Advanced Friction Welding Technology and Equipment, Harbin, ChinaNickel-based superalloys are indispensable in aerospace engines due to their exceptional high-temperature strength, oxidation resistance, and corrosion resistance, making them critical for joining processes such as inertia friction welding (IFW), which is favored for its efficiency and superior joint quality. In this study, IFW was used to join FGH101 powder superalloy with IN718 deformed superalloy, resulting in significant plastic deformation that formed symmetrical ear-shaped flash on the IN718 side and minor upsetting on the FGH101 side, with a wavy interface due to heat dissipation. Microhardness analysis revealed higher hardness at the weld interface, followed by a sharp decline near the Heat Affected Zone (HAZ) on the IN718 side due to phase re-dissolution, while FGH101 showed quicker recovery. Post-weld aging treatments enhanced hardness and strength through γ′ and δ phase precipitation in FGH101 and γ″ phases in IN718. Room temperature tensile tests demonstrated impressive strength with failures occurring plastically within the IN718 base metal, whereas elevated temperatures shifted failure locations to the weld zone without necking. Fatigue tests exhibited varied lifespans, with fractures initiating either at stress concentrators or within the FGH101 base metal far from the weld center. Scanning electron microscope (SEM) analysis confirmed mixed-mode fracture patterns, underscoring the importance of microstructure on joint performance and suggesting that optimizing IFW parameters can lead to superior weld quality in aerospace components, thus providing valuable insights for future research and industrial applications.https://www.frontiersin.org/articles/10.3389/fmats.2024.1544584/fulldissimilar metal weldinginertial friction weldingaeroenginemicrostructuresuperalloy |
| spellingShingle | Jun Zhou Jun Zhou Yongqiang Zhang Yongqiang Zhang Yongqiang Zhang Feng Qin Feng Qin Xuelong Zhang Xuelong Zhang Hao Wang Hao Wang Ze Liu Ze Liu Wenhan Zhang Wenhan Zhang Caiyan Huang Caiyan Huang Chunbo Zhang Chunbo Zhang Analysis of microstructural evolution and mechanical properties of FGH101 powder superalloy and IN718 deformed superalloy via inertia friction welding Frontiers in Materials dissimilar metal welding inertial friction welding aeroengine microstructure superalloy |
| title | Analysis of microstructural evolution and mechanical properties of FGH101 powder superalloy and IN718 deformed superalloy via inertia friction welding |
| title_full | Analysis of microstructural evolution and mechanical properties of FGH101 powder superalloy and IN718 deformed superalloy via inertia friction welding |
| title_fullStr | Analysis of microstructural evolution and mechanical properties of FGH101 powder superalloy and IN718 deformed superalloy via inertia friction welding |
| title_full_unstemmed | Analysis of microstructural evolution and mechanical properties of FGH101 powder superalloy and IN718 deformed superalloy via inertia friction welding |
| title_short | Analysis of microstructural evolution and mechanical properties of FGH101 powder superalloy and IN718 deformed superalloy via inertia friction welding |
| title_sort | analysis of microstructural evolution and mechanical properties of fgh101 powder superalloy and in718 deformed superalloy via inertia friction welding |
| topic | dissimilar metal welding inertial friction welding aeroengine microstructure superalloy |
| url | https://www.frontiersin.org/articles/10.3389/fmats.2024.1544584/full |
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