laser welding titanium-ss

8/10/2019 Laser Welding Titanium-SS

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Microstructures and mechanical property of laser butt welding

of titanium alloy to stainless steel

Shuhai Chen, Mingxin Zhang, Jihua Huang , Chengji Cui, Hua Zhang, Xingke Zhao

School of Materials Science and Engineering, University of Science and Technology Beijing, Beijing 100083, PR China

a r t i c l e i n f o

Article history:

Received 8 March 2013

Accepted 12 July 2013

Available online 24 July 2013

Keywords:

Laser welding

Titanium alloy

Stainless steel

Intermetallic compounds

a b s t r a c t

Laser butt welding of titanium alloy to stainless steel was performed. The effect of laser-beam offsetting

on microstructural characteristics and fracture behavior of the joint was investigated. It was found that

when the laser beam is offset toward the stainless steel side, it results in a more durable joint. The inter-

metallic compounds have a uniform thickness along the interface and can be divided into two layers. One

consists of FeTi + a-Ti, and other consists of FeTi + Fe2Ti + Ti5Fe17Cr5. When laser beam is offset by 0 mmand 0.3 mm toward the titanium alloy side, the joints fracture spontaneously after welding. Durable join-

ing is achieved only when the laser beam is offset by 0.6 mm toward the titanium alloy. From the top to

the bottom of the joint, the thickness of intermetallic compounds continuously decreases and the follow-

ing interfacial structures are found: FeAl + a-Ti/Fe2Ti + Ti5Fe17Cr5, FeAl +a-Ti/FeTi + Fe2Ti + Ti5Fe17Cr5and FeAl + a-Ti, in that order. The tensile strength of the joint is higher when the laser beam is offsettoward the stainless steel than toward the titanium alloy, the highest observed value being 150 MPa.

The fracture of the joint occurs along the interface between two adjacent intermetallic layers.

2013 Elsevier Ltd. All rights reserved.

1. Introduction

The joining of titanium alloy to conventional structural steel has

many industrial applications[1,2]. However, it is difficult to weld

titanium alloysto steel dueto great differencesin thermal, physical,

and chemical properties. According to the FeTi phase diagram[3],

the solubility of Fe in Ti is very low (0.1 at.%, at room temperature),

beyond which, intermetallic phases FeTiand then Fe2Ti (600 HVand

1000 HV respectively) begin to form [4]. These intermetallic phases

are highly brittle, causing conventional fusion-welded joints to

crack spontaneously, due to thermal-stress mismatch between the

two parent materials. Therefore, suppressing the formation of brit-

tle intermetallic compounds (IMCs) is the key to realizing reliable

joining. Diffusion bonding[5,6], brazing[7,8], and explosive weld-

ing [9,10] of steel and titanium has been investigated for thispurpose. These methods are effective to some extent in controlling

the formation of brittle intermetallic compounds, but their applica-

tions are restricted by joint configurations.

Friction stir welding is a novel solid-state welding method

which has been considered for joining titanium alloys to steel. Fa-

zel-Najafabadi et al. [11,12] achieved defect-free dissimilar lap

joints of CP-Ti to 304 stainless steel by adjusting friction-stir weld-

ing parameters. The maximum failure load of the joint reached 73%

of that of CP-Ti. Liao et al.[13]investigated the microstructures at

the interface of friction-stir lap joints of pure titanium and steel.

Swirling macro- and micro-intermixing zones of titanium and steel

were found along the interface, where tiny FeTi intermetallic par-

ticles were mixed with b titanium [13]. The investigations on

friction stir welding of titanium and steel focused mostly on the

lap configuration, but it was insufficient to study the butt

configuration.

Fusion welding, which is widely applied in industry, is con-

fronted with a great challenge in joining titanium alloys to steel.

In traditional arc welding, it is very difficult to control the molten

pool of titaniumsteel mixture, so a mass of intermetallic com-

pounds are formed during welding. Recently, the development of

high energy beam welding such as laser beam welding and elec-

tron beam (EB) wending have made fusion welding of titanium

alloy to steel possible.To reduce the residual tensile stress of the joint and improve

metallurgical reaction of the molten pool, copper was selected to

be the filler metal for electron beam welding of titanium alloy to

steel[14,15]. Electron beam welding needs to be performed in a

vacuum environment, which restricts its application. Laser weld-

ing, a new joining technology, has great advantages, such as high

efficiency, excellent controllability, and ability to be performed in

a non-vacuum environment. Hiraga et al.[16]applied a pulse laser

lap welding technique to join thin sheets of pure titanium and

stainless steel 304. Zhao et al.[17], suggested the laser lap welding

technique for joining titanium alloy to steel. They also obtained

further understanding of the welding process by FEM model

0261-3069/$ - see front matter 2013 Elsevier Ltd. All rights reserved.http://dx.doi.org/10.1016/j.matdes.2013.07.044

Corresponding author. Tel.: +86 010 62334859.

E-mail address: [email protected](J. Huang).

Materials and Design 53 (2014) 504511

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Materials and Design

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calculation. The laser butt welding of titanium alloy to steel need

Cu interlayer to improve metallurgical reaction and decrease resid-

ual stress. Tomashchuk et al.[18]reported that welding of Ti6Al4 V

to stainless steel AISI 316L through pure copper interlayer carried

out by pulsed Nd:YAG laser. The tensile strength of the welds is up

to 359 MPa and is limited by brittleness of CuTi2 + FeTi + a-Ti layersituated next to the solid Ti6Al4 V. Groza et al. [19] welded

X5CrNi1810 to Ti6Al4V through a copper foil, with the thick-ness of 600 lm, as intermediary layer by continuous NdYAG laser.The average value of tensile strength reached 328 Mpa. Thus, Using

Cu foil as an interlayer leads to acceptable strength characteristics

during laser welding of titanium alloy to steel.

Laser butt welding of titanium alloy to steel without filler metal

is not pay more attention. In fact, direct laser butt welding of tita-

nium alloy to steel is convenience in technology. Satoh et al.[20]

attempt to weld titanium alloy to stainless steel without filler me-

tal by laser welding, but tensile strengths of the joints were ob-

served to be lower than the base materials with failure occurring

through brittle fracture. And, investigation on the microstructures

is insufficient. To improve mechanical property of the joint, it is

necessary to understand deeply the weldability of titanium alloy

to steel without filler. Therefore, the weld characteristics and

microstructure should be investigated systematically.

The present work focuses on laser butt welding of titanium al-

loy to stainless steel without a filler metal. To control metallurgical

reactions in the molten pool, the welding experiments were per-

formed with various laser beam offsets, either toward the titanium

alloy or toward the stainless steel. The effect of laser beam offset

on the microstructural characteristics and mechanical property of

the joint was investigated.

2. Experiments

The plates of Ti6Al4V titanium alloy (100 50 1 mm3) and

201 stainless steel (100 50 1 mm3) were selected as laser

welding materials and their chemical compositions were showninTable 1. The plates manufacturing of titanium alloy and stainless

steel confirm to GB/T3621-94[21]and GB/T3280-92[22], respec-

tively. The interface sides of the specimens were carefully polished

and then clamped in a butt-weld geometry. A high-power (4 kW)

CO2laser with welding-head focal distance of 200 mm was used.

The laser beam was made to focus on the upper surfaces of the

specimens. All of the specimens were welded at a power of 2000 W

and a welding speed of 2 m/min to ensure full penetration of the

specimens. Influence of the laser beam offsets on the mechanical

property and microstructures of the joints were investigated be-

cause the formation of the intermetallic compounds is sensitive

to the offsets. The offsets toward stainless steel were defined as po-

sitive and those toward titanium alloy as negative, as shown in

Fig. 1a). In this study, welding with offsets of 0.6 mm,0.3 mm, 0 mm, 0.3 mm and 0.6 mm were performed.

The microstructures of the joint were observed by scanning

electron microscope (SEM) equipped with an energy-dispersive

X-ray spectrometer (EDS) which has 2% error for middle atom

number, after standard grinding and polishing procedures. Crystal

phases of the joints were identified by microbeam X-ray diffrac-

tometer (XRD). To increase diffracted intensity of the phases and

analyze broken position of the joints, the XRD tests were per-

formed at the fracture surface of the tensile specimen after tensile

test. The tensile strength of the joints at room temperature was

evaluated by a mechanical testing frame (INSTRON MODEL 1186)

at a cross head speed of 1 mm/min. The schematic diagram of

the tensile specimen is shown inFig 1b). The tensile test standards

are in accordance with ISO 6892: 1998[23].

3. Results

3.1. Weld appearance

Fig. 2shows the effect of the laser beam offsets on the surface

appearance of weld. When the offset is 0.6 mm (toward titanium

alloy), a durable joining was realized, as shown inFig. 2a. If the off-

sets are 0 mm and 0.3 mm (toward titanium alloy), the speci-

mens crackle noticeably during welding and then fractured

spontaneously after welding.Fig. 2b shows surface appearance of

the weld with a 0 mm offset. A number of cracks appear in the cen-

ter of the weld, resulting in spontaneous fracture after welding. It

appears that the weldability is bad when laser beam is offset to-

ward titanium alloy.

When the laser beam is offset toward stainless steel, all of the

specimens are joined durably, and the quality of the joint is im-

proved significantly. Fig. 2c shows the surface appearance of a

weld with a 0.6 mm offset. Compared to the 0.6 mm-offset weld,the surface appearance of weld is relatively smooth. The weld zone

was narrower because stainless steel has higher thermal conduc-

tivity (12.1 W/m K, 20C) than titanium alloy (5.44 W/m K, 20C)

[24]. Therefore, laser butt welding of titanium alloy to stainless

steel has better weldability when the laser beam is offset toward

stainless steel than toward titanium alloy.

Table 1

Chemical composition of materials used (wt%).

Name Fe C N H O Al V Ti

Titanium 60.3 60.1 60.05 60.015 60.2 5.56.8 3.54.5 rest

Name C Si Mn Cr N Ni P S Fe

Steel 60.15 60.75 5.57.5 16.018.0 60.25 3.55.5 60.03 60.06 rest

Fig. 1. Schematic diagram of laser welding of titanium alloy to stainless steel. (a)

The process and (b) tensile specimen (thickness: 1 mm).

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of Al, as shown inTable 2. Zones E and F can then be considered a

FeCrTi ternary system and phase compositions can thus be con-

firmed. The locations of these phases on the FeCrTi ternaryphase diagram [26] are as shown by E and F in Fig. 5. It can be

deduced that the light grey phase (E zone) and the white phase

(F zone) are Fe2Ti ands (Ti5Fe17Cr5), respectively.It can be seen that gray phases (D zone) and light grey phase (E

zone) are Fe2Ti phases. The contrast difference of the phases is

caused by different average atom numbers between D and C zones.

Therefore, interfacial structures of the joint are FeAl + Ti/

FeTi + Fe2Ti + Ti5Fe17Cr5.

3.2.2. Offset toward titanium alloy

Fig. 6shows the microstructures of the joint made by the laser

beam offset of 0.6 mm toward titanium alloy. Complex structures

appear at the interface. First, partial melting of stainless steel

Fig. 5. Liquidus surface of the FeCrTi ternary phase diagram[26].

Table 2

EDS results of the joints (at.%).

Position Ti Fe Cr Ni V Al

A 57.51 24.31 5.31 1.78 1.52 9.57

B 60.77 20.90 5.58 2.10 1.77 8.87

C 49.58 32.18 7.06 3.22 1.14 6.83

D 40.92 36.38 9.97 5.18 1.59 5.96

E 25.99 51.31 11.84 7.17 0.49 3.13

F 12.24 58.87 18.55 5.73 1.01 3.60

G 27.35 53.44 13.36 3.47 0.64 1.73

H 15.71 57.34 19.17 4.85 0.53 2.40

I 4.43 66.06 22.55 4.95 0.69 1.32

J 70.02 21.06 7.97 0.24 0.70

Fig. 4. Liquidus surface of the FeTiAl ternary phase diagram [25].

Fig. 6. Microstructures of the joint at the offset of laser beam toward to titanium

alloy. (a) Macro cross-section, (b) microstructures at the top of the joint and (c)microstructures at the bottom of the joint.

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appears at the top of the joint, as shown inFig. 6a. Second, the

thickness gradually decreases from the top to the end of the joint.

Third, different interfacial structures appear at the top, middle and

bottom of the joint. At the top of the joint inFig. 6b, two reaction

layers are formed. A grey layer is close to the fusion zone, defined

as Layer III in this paper. It can be deduced that the phase com-

positions of Layer III is same with Layer I because they have the

same morphology. The other white layer is close to stainless steel,defined as Layer IV. In this layer, a light grey dendritic structure

grows into Layer IV from the interface of Layer III and Layer IV. A

light grey fusion line appears between Layer IV and parent stain-

less steel. In the middle of the joint indicated by a rectangle in

Fig. 6b, the interfacial structures are the same as that made by

the laser beam offset toward stainless steel, as shown in Fig. 3b.

The structures consist of two layers of FeAl + Ti/FeTi + Fe 2Ti + Ti5-Fe17Cr5. At the bottom of the joint inFig. 6c, only one reaction layer

is formed between titanium alloy and stainless steel. It is con-

firmed that this layer has same structures with Layer I (FeAl + Ti).

According to above observation on the microstructures of the

joint, the phase compositions of Layer IV need to be confirmed.

In Layer IV, since the Al content is relatively low, the phase compo-

sitions can be identified as a FeCrTi ternary system. The compo-

sitions of the grey dendritic phase growing into Layer IV (G zone)

and white phase of the Layer IV (H zone) in the FeCrTi ternary

phase diagram are shown by D and E in Fig. 4. It can be believed

that the grey dendritic phase is Fe2Ti and the white phase is ter-

nary intermetallic compound s (Ti5Fe17Cr5). At fusion line (I zone),

the content of Ti slightly increases, compared to parent stainless

steel (J zone).

Therefore, the interfacial structures of the joint are from the top

to the bottom confirmed orderly as FeAl + Ti/Fe2Ti + Ti5Fe17Cr5?

FeAl + Ti/ FeTi + Fe2Ti + Ti5Fe17Cr5? FeAl + Ti.

3.3. mechanical property of the joint

To evaluate the mechanical property of the joint, tensilestrength tests were performed.Fig. 7 shows the influence of la-

ser-beam offsets on the tensile strength of the joints. Because the

specimens with the offsets of0.3 mm and 0 mm fracture sponta-

neous after the welding, the tensile strength is zero. When the off-

set is 0.6 mm, the tensile strength of the joint is only 24.75 MPa.

In contrast, when the offsets are 0.3 mm and 0.6 mm, the tensile

strength of the joints increase significantly. When laser beam is

offset to 0.6 mm toward stainless steel, the tensile strength of

the joint reaches 150 MPa. Therefore, the joints have higher tensile

strength when the laser beam is offset toward the stainless steel

than the toward the titanium alloy.

3.4. Fracture behavior of the joint

Fig. 8shows fracture surface of the joint made with laser-beam

offset of 0.6 mm toward titanium alloy. The fracture exhibits typi-

cal brittle characteristics. A relatively smooth fracture surface witha river patten appears at the top of the joint. In contrast, the frac-

ture at the middle and end of the joint exhibits relatively rough

morphology. In addition, many cracks along the thickness direction

of the plate appear at the fracture surface. When the offset is

0.6 mm toward stainless steel, the fracture morphology still exhib-

its typical brittle characteristics. However, the relatively smooth

fracture surface with river patten disappears and all fracture sur-

face becomes to relatively rough, as shown in Fig. 9. Also, the

cracks along the thickness direction of the plate is more dense than

that with laser beam offset of 0.6 mm toward titanium.

To confirm phase compositions at the fracture surface, XRD was

performed on all the samples, as shown inFig. 10. Because there

are complex element compositions of the joints, distortion of crys-

tal lattice is inevitable. Thus, the location of the diffraction peaks ofthe phase compositions may be offset from the location of the stan-

dard diffraction peak. It was found that a-Ti and Fe2Ti appear at allof the fracture surfaces. Theb-Ti do not appears at the fracture sur-

faces, which indicates that theb-Ti in the eutectic structures ofb-Ti

and FeTi transforms into a-Ti during the cooling of the weld.Therefore, it is confirmed that the Layer I consists ofa-Ti and FeTi.

The presence of the a-Ti at all fracture surfaces may indicate-that the joint fractures along the layer which containsa-Ti and FeTi(Layer I or Layer III). However, the presence of the Fe2Ti seems to

indicate that the joint fractures along Layer II or Layer IV. There-

fore, it can be concluded that fracture only occurs along the inter-

face between two adjacent layers.

It should be noted that some of the phases observed in SEM

were not found by the XRD. In general, the XRD results dependon diffracted intensity of the phases. Thus, the XRD were per-

formed at fracture surface to increase the diffracted intensity

[27]. However, some of the intermetallic compounds in this study

are uncontinuous and inhomogeneous in distribution, such as Ti5-Fe17Cr5. And, the content is relatively low. Therefore, some of the

phases maybe are not found by the XRD, although the XRD were

performed at fracture surface.

4. Discussion

When titanium alloy is mixed with the stainless steel in the li-

quid state, a number of brittle intermetallic compounds are formed

inside fusion zone during welding. Meanwhile, a stress mismatch

arises in the seam due to great difference in thermal expansioncoefficients between titanium alloy (7.89 106/C) and stainless

steel (16.9 106/C)[24]. The specimens fracture spontaneously

when a sufficient amount of intermetallic compounds has formed.

To improve the weldability of titanium alloy to steel, the Cu inter-

layer was used during laser welding[18,19]. On the one hand, the

Cu interlayer improved metallurgical reaction of weld pool, which

leads to the formation of TiCu intermetallic compounds[19]. On

the other hand, the interlayer decrease residual stress of the joint

[14]. Therefore, the tensile strength of the joint with the Cu inter-

layer reached to 359 MPa[18].

Outside using the Cu interlayer, suppressing liquid-state mixing

between titanium alloy and steel is an important way to realize

strong joining. Satoh et al.[20]attempted to weld titanium alloy to

steel without interlayer by Nd: YAG laser welding, but liquid-statesmixing between titanium alloy and steel is not suppressed fully.Fig. 7. Influence of the offset of laser beam on the tensile strength.

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Perhaps samples were processed at laser beam offsets from the

interfacetowardthe Tiplate,which isnot goodway proved inthispa-per. In our study, the liquid-states mixing is suppressed better by

controlling laser beam offset toward titaniumalloy. Thus, laser beam

offsetting toward titanium alloy is an effective way to suppress li-quid-state mixing during welding of titanium alloy to stainless steel.

Fig. 8. Fracture surface of the joint with laser beam offset of 0.6 mm toward to

titanium. (a) Macro fracture surface, (b) magnification of P1 zone and (c)

magnification of P2 zone.

Fig. 9. Fracture surface of the joint with the offset of 0.6 mm toward to stainless

steel. (a) Macro fracture surface, (b) magnification of P3 zone and (c) magnification

P4 zone.

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According to the results of the experiment, laser butt welding of

titanium alloy to stainless steel has better weldability when the

laser beam is offset toward stainless steel than toward titanium

alloy. This is closely related to the distribution and compositions

of the intermetallic compounds, which depend on the laser beam

offsets.

The intermetallic compounds along the interface between

titanium alloy and stainless steel are more uniform in thickness

when the laser beam is offset toward stainless steel than when

it is offset toward titanium alloy. This difference in thickness isa result of great difference in thermal conductivity between

stainless steel (12.1 W/m K, 20C) and titanium alloy (5.44 W/

m K, 20 C)[24]. Stainless steel has a higher thermal conductivity

than titanium alloy, which means that the thermal conduction

from the high temperature zone of the molten pool to the low

temperature zone is easier when laser beam is offset toward

the stainless steel rather than titanium. Thus, a more uniform

temperature distribution is achieved when the laser beam is off-

set toward stainless steel, which is the side with higher thermal

conductivity. The low temperature gradient along the interface

induces uniform thickness of intermetallic compounds. The

uneven thickness distribution of the intermetallic compounds

has negative influence on the mechanical property of the joint.

First, it causes an uneven distribution of residual stress in theseam, compared to the joint with uniform distribution of the

intermetallic compounds. Furthermore, stress concentration is

induced inside the seam. The residual stress compromises

mechanical property of the joint. Second, the residual stress

causes cracks to initiate at the top of the joint, where the thick

intermetallic compounds layer is. In particular, this causes the

specimens with the 0.3 mm and 0 mm offsets fracture sponta-

neously after welding. Third, the uneven thickness distribution

of the intermetallic compounds makes it more difficult to

control mechanical property of the joint: when the amount inter-

metallic compounds at the top of the joint are limited to a

reasonable level, the bottom of the joint would not have been

reliably welded yet; when the bottom of the joint is welded with

a reasonable amount of intermetallics, too much intermetallicswould have formed on the top of the joint. Therefore, the joint

with uniform thickness of intermetallic compounds, made by a

laser beam offset toward the stainless steel, has high tensile

strength.

When the laser beam is offset toward titanium alloy, the rela-

tively smooth fracture surface with river patten at the top of the

joint indicates that the crack propagation only required low en-

ergy, as shown inFig. 8b. The low propagation energy of the crack

leads to low tensile strength of the joint. According to the micro-

structures inFig. 6, slight melting appears at the top of the joint,

which indicates the mixing between titanium alloy and stainlesssteel. This proves that the mixing between titanium alloy and

stainless steel adversely affects the mechanical property of the

joint. The fracture morphologies when laser beam is offset toward

titanium alloy are similar with that observed by Satoh et al.[20],

because similar processing parameters were used. Meanwhile, the

phase compositions of this zone (FeAl +a-Ti/Fe2Ti + Ti5Fe17Cr5)greatly differ with other areas (FeAl +a-Ti/FeTi + Fe2Ti + Ti5Fe17Cr5 or FeAl + a-Ti) of the joint. Therefore, phase compositionmay be another important factor which contributes to low tensile

strength of joint made when the laser beam is offset toward the

titanium alloy.

5. Conclusions

From the investigation on microstructures and mechanical

property of laser butt welding of titanium alloy to stainless steel,

conclusions were summarized as following:

(1) When thelaser beam is offsettoward thestainless steel,dura-

ble joining is realized. The intermetallic compounds have

uniform thickness along the interfaceand canbe divided into

two layers: FeTi + a-Ti and FeTi + Fe2Ti + Ti5Fe17Cr5.(2) When the laser beam is offset by 0 mm and 0.3 mm toward

the titanium alloy, the joints fracture spontaneously subse-

quent to welding. Durable joining is obtained only when

the laser beam is offset by 0.6 mm toward the titanium alloy.

From the top to the bottom of the joint, the thickness ofintermetallic compounds continuously decreases and the

Fig. 10. XRD patterns of fracture surface of the joint. (a) 0.6 mm, (b) 0.3 mm, (c) 0.3 mm and (d) 0.6 mm.

510 S. Chen et al. / Materials and Design 53 (2014) 504511


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following interfacial structures are found: FeAl +a-Ti/Fe2Ti + Ti5Fe17Cr5, FeAl + a-Ti/FeTi + Fe2Ti + Ti5Fe17Cr5 andFeAl + a-Ti, in that order.

(3) The tensile strength of the joint is higher when the laser

beam is offset toward stainless steel than toward titanium

alloy, the highest value being 150 MPa. Fracture occurs along

the interface between two adjacent layers.

Acknowledgments

The authors appreciate the financial support from the National

Natural Science Foundation of China (No. 51004009) and the Fun-

damental Research Funds for the Central Universities (FRF-TP-12-

044A). The authors would like to express their gratitude to Dr. Bert

Liu, Department of Materials Science and Engineering, The Ohio

State University, for his help in English revision of this article.

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