Frontier Materials & Technologies. 2022; : 102-112
Влияние формы заготовок на остаточные напряжения при линейной сварке трением
https://doi.org/10.18323/2782-4039-2022-4-102-112Аннотация
Линейная сварка трением – перспективная технология изготовления титановых моноколес компрессоров газотурбинных двигателей, к которым предъявляются жесткие требования по циклической прочности и точности размеров. Перспективным является направление по замене традиционно применяемых стыковых соединений на более технологичные Т-образные, которые обеспечат снижение затрат на обработку деталей перед сваркой. Внедрение Т-образных соединений требует дополнительных исследований специфики распределения тепла, формирования напряженно-деформированного состояния в процессе и после сварки. В связи с этим актуальны исследования остаточных напряжений в Т-образных соединениях титановых сплавов, полученных линейной сваркой трением. В работе исследуются остаточные напряжения в соединении, имитирующем соединение лопатка – диск. Рассматриваются результаты сварки, где на детали, имитирующей лопатку, выфрезерован рельеф меньшего сечения. Предложена конечно-элементная модель, охватывающая стадии проковки, охлаждения и снятия деталей со сборочного приспособления. Модель разработана в пакете ANSYS Workbench и описывает напряженно-деформированное состояние сваренных деталей, позволяя оценить распределение и уровень остаточных сварочных напряжений. Отличительной особенностью модели является учет несимметричного распределения температуры, полученный конечно-разностным решением тепловой задачи сварки Т-образного соединения, а также имитация формы шва, полученная в результате металлографических исследований сваренных образцов. Представленная модель позволяет оценить остаточные напряжения в соединениях. Распределения остаточных напряжений в исследованных Т-образных соединениях отличаются от таковой в стыковых – во всех исследованных случаях в сварном шве действуют сжимающие напряжения, уравновешивающиеся растягивающими, действующими на расстоянии 1 мм от стыка. Формирование сжимающих напряжений в сварном шве обусловлено пластической деформацией под действием ковочного усилия.
Список литературы
1. Tabatabaeian A., Ghasemi A.R., Shokrieh M.M., Marzbanrad B., Baraheni M., Fotouhi M. Residual Stress in Engineering Materials: A Review // Advanced engineering materials. 2022. Vol. 24. № 3. Article number 2100786. DOI: 10.1002/adem.202100786.
2. McAndrew A.R., Colegrove P.A., Bühr C., Flipo B.C.D., Vairis A. A literature review of Ti-6Al-4V linear friction welding // Progress in Materials Science. 2018. Vol. 92. P. 225–257. DOI: 10.1016/j.pmatsci.2017.10.003.
3. Frankel P., Preuss M., Steuwer A., Withers P.J., Bray S. Comparison of residual stresses in Ti-6Al-4V and Ti-6Al-2Sn-4Zr-2Mo linear friction welds // Materials Science and Technology. 2009. Vol. 25. № 5. P. 640–650. DOI: 10.1179/174328408X332825.
4. Romero J., Attallah M.M., Preuss M., Karadge M., Bray S.E. Effect of the forging pressure on the microstructure and residual stress development in Ti-6Al-4V linear friction welds // Acta Materialia. 2009. Vol. 57. № 18. P. 5582–5592. DOI: 10.1016/j.actamat.2009.07.055.
5. Liu C., Dong C.-L. Internal residual stress measurement on linear friction welding of titanium alloy plates with contour method // Transactions of Nonferrous Metals Society of China (English Edition). 2014. Vol. 24. № 5. P. 1387–1392. DOI: 10.1016/S1003-6326(14)63203-9.
6. Daymond M.R., Bonner N.W. Measurement of strain in a titanium linear friction weld by neutron diffraction // Physica B: Condensed Matter. 2003. Vol. 325. P. 130–137. DOI: 10.1016/S0921-4526(02)01514-4.
7. Gadallah R., Tsutsumi S., Aoki Y., Fujii H. Investigation of residual stress within linear friction welded steel sheets by alternating pressure via X-ray diffraction and contour method approaches // Journal of Manufacturing Processes. 2021. Vol. 64. P. 1223–1234. DOI: 10.1016/j.jmapro.2021.02.055.
8. Song X., Xie M., Hofmann F., Jun T.S., Connolley T., Reinhard C., Atwood R.C., Connor L., Drakopoulos M., Harding S., Korsunsky A.M. Residual stresses in Linear Friction Welding of aluminium alloys // Materials and Design. 2013. Vol. 50. P. 360–369. DOI: 10.1016/j.matdes.2013.03.051.
9. Turner R., Ward R.M., March R., Reed R.C. The magnitude and origin of residual stress in Ti-6Al-4V linear friction welds: An investigation by validated numerical modeling // Metallurgical and materials transactions B: Process Metallurgy and Materials Processing Science. 2012. Vol. 43. № 1. P. 186–197. DOI: 10.1007/s11663-011-9563-9.
10. Bühr C., Ahmad B., Colegrove P.A., McAndrew A.R., Guo H., Zhang X. Prediction of residual stress within linear friction welds using a computationally efficient modelling approach // Materials and Design. 2018. Vol. 139. P. 222–233. DOI: 10.1016/j.matdes.2017.11.013.
11. Geng P., Qin G., Zhou J. A computational modeling of fully friction contact-interaction in linear friction welding of Ni-based superalloys // Materials and Design. 2020. Vol. 185. Article number 108244. DOI: 10.1016/j.matdes.2019.108244.
12. Lee L.A., McAndrew A.R., Buhr C., Beamish K.A., Colegrove P.A. 2D linear friction weld modelling of a Ti-6Al-4V T-joint // Journal of Engineering Science and Technology Review. 2015. Vol. 8. № 6. P. 44–48. DOI: 10.25103/jestr.086.12.
13. Li W., Vairis A., Preuss M., Ma T. Linear and rotary friction welding review // International Materials Reviews. 2016. Vol. 61. № 2. P. 71–100. DOI: 10.1080/09506608.2015.1109214.
14. Li W.-Y., Ma T., Li J. Numerical simulation of linear friction welding of titanium alloy: Effects of processing parameters // Materials and Design. 2010. Vol. 31. № 3. P. 1497–1507. DOI: 10.1016/j.matdes.2009.08.023.
15. Schröder F., Ward R.M., Walpole A.R., Turner R.P., Attallah M.M., Gebelin J.-C., Reed R.C. Linear friction welding of Ti6Al4V: experiments and modeling // Materials Science and Technology. 2015. Vol. 31. № 3. P. 372–384. DOI: 10.1179/1743284714Y.0000000575.
16. McAndrew A.R., Colegrove P.A., Addison A.C., Flipo B.C.D., Russel M.J. Energy and force analysis of Ti-6Al-4V linear friction welds for computational modeling input and validation data // Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science. 2014. Vol. 45. № 13. P. 6118–6128. DOI: 10.1007/s11661-014-2575-8.
17. Bühr C., Colegrove P.A., McAndrew A.R. A computationally efficient thermal modelling approach of the linear friction welding process // Journal of Materials Processing Technology. 2018. Vol. 252. P. 849–858. DOI: 10.1016/j.jmatprotec.2017.09.013.
18. Medvedev A.U., Galimov V.R., Gatiyatullin I.M., Murugova O.V. Finite difference model of temperature fields in linear friction welding // Solid State Phenomena. 2020. Vol. 303. P. 175–180. DOI: 10.4028/www.scientific.net/ssp.303.175.
19. Nikiforov R., Medvedev A., Tarasenko E., Vairis A. Numerical simulation of residual stresses in linear friction welded joints // Journal of Engineering Science and Technology Review. 2015. Vol. 8. № 6. P. 49–53. DOI: 10.25103/jestr.086.13.
20. Pervaiz S., Deiab, I., Wahba, E., Rashid A., Nicolescu M. A numerical and experimental study to investigate convective heat transfer and associated cutting temperature distribution in single point turning // International Journal of Advanced Manufacturing Technology. 2018. Vol. 94. № 1-4. P. 897–910. DOI: 10.1007/s00170-017-0975-9.
Frontier Materials & Technologies. 2022; : 102-112
The influence of a workpiece shape on residual stresses during linear friction welding
https://doi.org/10.18323/2782-4039-2022-4-102-112Abstract
Linear friction welding is an advanced technology for manufacturing titanium blisks for gas-turbine engine compressors, which are subjected to stringent requirements for cyclic strength and dimensional accuracy. Substitution of conventional butt joints with more technological T-shape joints is a promising area, which provides reducing of the pre-welding machining costs. The introduction of T-form joints requires additional research of thermal distribution specifics and strain-stress state formation in the welding process and after its end. Therefore, the study of residual stresses in titanium alloy T-shape joints produced by linear friction welding is topical. The paper investigates the residual stresses in imitating welded blisk joints. The authors consider the results of welding where the blade imitator has a reamed relief of a smaller section. The finite element model covering forging, cooling, and disassembly of welded specimens is offered. The authors developed the model in ANSYS Workbench to describe the strain-stress state of welded specimens, which allows for estimating the residual stress levels and spreading. The main distinctive feature of the model is an accounting of asymmetric temperature distribution obtained by finite-difference solving of a T-shape joint thermal problem and weld shape simulation obtained as a result of welded joints metallographic research. The presented model allows the evaluation of the residual stresses in joints. The distribution of residual stresses in T-shaped welded joints is specific – compressive stresses existing in a weld are balanced by tensile stresses acting at a distance of 1 mm from the joint. The formation of compressive stresses in a weld is caused by plastic deformation due to the forging force action.
References
1. Tabatabaeian A., Ghasemi A.R., Shokrieh M.M., Marzbanrad B., Baraheni M., Fotouhi M. Residual Stress in Engineering Materials: A Review // Advanced engineering materials. 2022. Vol. 24. № 3. Article number 2100786. DOI: 10.1002/adem.202100786.
2. McAndrew A.R., Colegrove P.A., Bühr C., Flipo B.C.D., Vairis A. A literature review of Ti-6Al-4V linear friction welding // Progress in Materials Science. 2018. Vol. 92. P. 225–257. DOI: 10.1016/j.pmatsci.2017.10.003.
3. Frankel P., Preuss M., Steuwer A., Withers P.J., Bray S. Comparison of residual stresses in Ti-6Al-4V and Ti-6Al-2Sn-4Zr-2Mo linear friction welds // Materials Science and Technology. 2009. Vol. 25. № 5. P. 640–650. DOI: 10.1179/174328408X332825.
4. Romero J., Attallah M.M., Preuss M., Karadge M., Bray S.E. Effect of the forging pressure on the microstructure and residual stress development in Ti-6Al-4V linear friction welds // Acta Materialia. 2009. Vol. 57. № 18. P. 5582–5592. DOI: 10.1016/j.actamat.2009.07.055.
5. Liu C., Dong C.-L. Internal residual stress measurement on linear friction welding of titanium alloy plates with contour method // Transactions of Nonferrous Metals Society of China (English Edition). 2014. Vol. 24. № 5. P. 1387–1392. DOI: 10.1016/S1003-6326(14)63203-9.
6. Daymond M.R., Bonner N.W. Measurement of strain in a titanium linear friction weld by neutron diffraction // Physica B: Condensed Matter. 2003. Vol. 325. P. 130–137. DOI: 10.1016/S0921-4526(02)01514-4.
7. Gadallah R., Tsutsumi S., Aoki Y., Fujii H. Investigation of residual stress within linear friction welded steel sheets by alternating pressure via X-ray diffraction and contour method approaches // Journal of Manufacturing Processes. 2021. Vol. 64. P. 1223–1234. DOI: 10.1016/j.jmapro.2021.02.055.
8. Song X., Xie M., Hofmann F., Jun T.S., Connolley T., Reinhard C., Atwood R.C., Connor L., Drakopoulos M., Harding S., Korsunsky A.M. Residual stresses in Linear Friction Welding of aluminium alloys // Materials and Design. 2013. Vol. 50. P. 360–369. DOI: 10.1016/j.matdes.2013.03.051.
9. Turner R., Ward R.M., March R., Reed R.C. The magnitude and origin of residual stress in Ti-6Al-4V linear friction welds: An investigation by validated numerical modeling // Metallurgical and materials transactions B: Process Metallurgy and Materials Processing Science. 2012. Vol. 43. № 1. P. 186–197. DOI: 10.1007/s11663-011-9563-9.
10. Bühr C., Ahmad B., Colegrove P.A., McAndrew A.R., Guo H., Zhang X. Prediction of residual stress within linear friction welds using a computationally efficient modelling approach // Materials and Design. 2018. Vol. 139. P. 222–233. DOI: 10.1016/j.matdes.2017.11.013.
11. Geng P., Qin G., Zhou J. A computational modeling of fully friction contact-interaction in linear friction welding of Ni-based superalloys // Materials and Design. 2020. Vol. 185. Article number 108244. DOI: 10.1016/j.matdes.2019.108244.
12. Lee L.A., McAndrew A.R., Buhr C., Beamish K.A., Colegrove P.A. 2D linear friction weld modelling of a Ti-6Al-4V T-joint // Journal of Engineering Science and Technology Review. 2015. Vol. 8. № 6. P. 44–48. DOI: 10.25103/jestr.086.12.
13. Li W., Vairis A., Preuss M., Ma T. Linear and rotary friction welding review // International Materials Reviews. 2016. Vol. 61. № 2. P. 71–100. DOI: 10.1080/09506608.2015.1109214.
14. Li W.-Y., Ma T., Li J. Numerical simulation of linear friction welding of titanium alloy: Effects of processing parameters // Materials and Design. 2010. Vol. 31. № 3. P. 1497–1507. DOI: 10.1016/j.matdes.2009.08.023.
15. Schröder F., Ward R.M., Walpole A.R., Turner R.P., Attallah M.M., Gebelin J.-C., Reed R.C. Linear friction welding of Ti6Al4V: experiments and modeling // Materials Science and Technology. 2015. Vol. 31. № 3. P. 372–384. DOI: 10.1179/1743284714Y.0000000575.
16. McAndrew A.R., Colegrove P.A., Addison A.C., Flipo B.C.D., Russel M.J. Energy and force analysis of Ti-6Al-4V linear friction welds for computational modeling input and validation data // Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science. 2014. Vol. 45. № 13. P. 6118–6128. DOI: 10.1007/s11661-014-2575-8.
17. Bühr C., Colegrove P.A., McAndrew A.R. A computationally efficient thermal modelling approach of the linear friction welding process // Journal of Materials Processing Technology. 2018. Vol. 252. P. 849–858. DOI: 10.1016/j.jmatprotec.2017.09.013.
18. Medvedev A.U., Galimov V.R., Gatiyatullin I.M., Murugova O.V. Finite difference model of temperature fields in linear friction welding // Solid State Phenomena. 2020. Vol. 303. P. 175–180. DOI: 10.4028/www.scientific.net/ssp.303.175.
19. Nikiforov R., Medvedev A., Tarasenko E., Vairis A. Numerical simulation of residual stresses in linear friction welded joints // Journal of Engineering Science and Technology Review. 2015. Vol. 8. № 6. P. 49–53. DOI: 10.25103/jestr.086.13.
20. Pervaiz S., Deiab, I., Wahba, E., Rashid A., Nicolescu M. A numerical and experimental study to investigate convective heat transfer and associated cutting temperature distribution in single point turning // International Journal of Advanced Manufacturing Technology. 2018. Vol. 94. № 1-4. P. 897–910. DOI: 10.1007/s00170-017-0975-9.
