A review of linear friction welding of Ni-based superalloys

A review of linear friction welding of Ni-based superalloys

June 2024 | Xiawei Yang, Tingxi Meng, Qiang Chu, Yu Su, Zhenguo Guo, Rui Xu, Wenlong Fan, Tiejun Ma, and Wenyu Li
This review summarizes the current state of research on linear friction welding (LFW) of Ni-based superalloys. Ni-based superalloys are crucial materials in aerospace and nuclear energy due to their high-temperature strength, oxidation resistance, and corrosion resistance. LFW is a solid-state welding technique that avoids melting and solidification, thus avoiding issues like solidification cracking and porosity. It is suitable for joining a wide range of materials, including steels, superalloys, titanium alloys, and aluminum alloys. The LFW process involves reciprocal motion between a stationary component and a moving workpiece under force, and it consists of four stages: initial, transition, equilibrium, and deceleration. The process generates frictional heat and extrusion deformation, leading to the formation of a flash. The flash morphology is influenced by factors such as friction time and material properties. The LFW process offers advantages in manufacturing integral blisks, reducing component weight and eliminating mechanical interfaces that can cause fatigue cracks. Recent studies have focused on numerical simulations of the LFW process, with 2D and 3D models used to understand deformation behavior, temperature fields, stress fields, and strain fields. A 3D model with 30,000 tetrahedral elements was found to be more accurate for simulating LFW of Ni-based superalloys. The review highlights the importance of understanding the microstructures, mechanical properties, and other characteristics of LFWed Ni-based superalloys to optimize the LFW process for future applications. The findings contribute to a better understanding of the LFW process and its potential in the manufacturing of high-performance components.This review summarizes the current state of research on linear friction welding (LFW) of Ni-based superalloys. Ni-based superalloys are crucial materials in aerospace and nuclear energy due to their high-temperature strength, oxidation resistance, and corrosion resistance. LFW is a solid-state welding technique that avoids melting and solidification, thus avoiding issues like solidification cracking and porosity. It is suitable for joining a wide range of materials, including steels, superalloys, titanium alloys, and aluminum alloys. The LFW process involves reciprocal motion between a stationary component and a moving workpiece under force, and it consists of four stages: initial, transition, equilibrium, and deceleration. The process generates frictional heat and extrusion deformation, leading to the formation of a flash. The flash morphology is influenced by factors such as friction time and material properties. The LFW process offers advantages in manufacturing integral blisks, reducing component weight and eliminating mechanical interfaces that can cause fatigue cracks. Recent studies have focused on numerical simulations of the LFW process, with 2D and 3D models used to understand deformation behavior, temperature fields, stress fields, and strain fields. A 3D model with 30,000 tetrahedral elements was found to be more accurate for simulating LFW of Ni-based superalloys. The review highlights the importance of understanding the microstructures, mechanical properties, and other characteristics of LFWed Ni-based superalloys to optimize the LFW process for future applications. The findings contribute to a better understanding of the LFW process and its potential in the manufacturing of high-performance components.
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