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Introduction
In recent years, joining of dissimilar metals is gradually investigated because it is
capable of offering complex functions and finding applications in variety of fields
such as thermal power station, nuclear industries, petrochemical industries,
aerospace, microelectronics, automobile etc.
For example, aluminium and magnesium alloys are used by automobile industries
because they are attractive as lightweight structural materials to achieve high
performances and efficiency. However, steels are still widely used as structural
materials due to their high absolute strength and good cost efficiency. Therefore , it
is becoming very important to join Al or Mg alloys to steel to fabricate structural
components, and dissimilar welding technology is necessary.
With the increasing use of Ti and its alloys in aerospace, transportation, power
generation and chemical industries because of their high strength to weight ratio
and excellent corrosion resistance, there is an obvious requirement to join them to
other dissimilar metals.
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Introduction
In particular, the joining of Ti to structural steels with high strength and toughness
is of considerable importance for the integration and fabrication of Ti-base
components, although a conventional fusion welding has not been technically
usable.
Titanium to stainless steel joints have applications in chemical and nuclear industry.
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Literature Review
Table.1: List of researches performed in past 2o years
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CP Titanium
Table.3: Properties of CP Titanium
Low density
Mechanical Properties
Fe 0.2
C 0.08
steel. SS 304 is the most widely used austenitic Melting Point 1400-1455 oC
locomotives. Fe 66.345-75
Mn Max 2
Ni 8-10.5
P Max 0.045
S Max 0.03
9 Si Max 1
Initial Trials
Initially we tried to weld commercially pure
titanium and stainless steel (SS 304) plates,
both having dimension of 100 mm*50 mm*2
mm using GTAW welding in butt joint fashion
without any filler on interlayer metal at given
parameters.
(mm/sec)
1 145 2 2.4
2 160 3 2.4
3 181 4 2.4 Figure.1: Front and back view of gas tungsten arc welded
sample 3 without any filler metal.
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Reason for the failure of experiment
From table as well as binary
phase diagram, we can see
the possible phases which
can be formed. From further
study we found that two of
the phases TiFe and TiFe2 is
very hard and brittle in
nature.
Table.6: Phases forms during interaction of
Fe and Ti at different wt%
Ti 0 to 0.047
Ti 0 to 24.7
Intensity (counts)
find the phases
formed.
4.0e+003
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Proposed solution of the problem
Weld Process Control
Weld Metal Engineering
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Adopted solution of the problem
Our present work proposed weld metal engineering technique to
improve the mechanical properties of titanium to stainless steel welded
joint.
Copper was selected as transition metal due to its lower melting point vs
mechanical properties relationship when compared to other transition
metal like Ag and Ni. Cu is compatible with Fe, and the intermetallic
compounds produced with Ti are tougher than Fe-Ti intermetallic
compounds
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Reasons for selecting Copper
From ternary phase
diagram, we got to know
about different intermetallic
compounds possibilities
between these three
elements. We studied about
the properties of the
intermetallic compounds
and found that its tougher
than the Fe-Ti intermetallic
compounds and good
affinity towards each other.
Where H is the enthalpy, T is the atmospheric temperature and S is the entropy. In solid
state bonding, change in enthalpy is equal to change in Gibbs free energy as entropy is
the order of 0.001 kJ/deg/mol [10] and hence
So from Miedemas equation and plot we found that enthalpy difference between Cu-
Steel is positive (H= +60kJ/mole) and same goes for enthalpy difference between Cu-
Ti which is also positive. So it proves that the tendency of formation of intermetallic
compounds is low for Cu-Steel and Cu-Ti. So it verified our choice of taking copper as a
transition metal between commercially pure titanium and stainless steel.
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Copper
Pure copper is tough, malleable Table.7: Properties of Commercially Pure Copper.
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Experimentation
A thin copper piece of rectangular cross-section is place between CP Titanium-and
SS 304 plates, both having dimension of 100 mm*50 mm*2 mm. Whole
arrangement is placed over the copper backing plate. Copper fillers height is taken
3mm and width is varied from 0.1 mm to 3.5 mm for automatic gas tungsten arc
welding.
Figure.5: Gas tungsten arc welding setup [source IDC workshop IIT (BHU) Varanasi]
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Experimentation
Figure.6: Front view of welding trolley and welding torch setup Figure.7: Arrangement of CP Titanium and stainless steel 304
with clamping arrangement. plate with copper strip having copper as a backing plate.
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Experimentation
copper strip throughout Parameters Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Sample 6
the experiment at
different parameters. We Current Ampere Rating 160 160 120 120 120 140
but at the same time a) Thickness (mm) 3.0 3.0 3.0 3.0 3.0 3.0
without any formation of
Welding Speed (mm/s) 3 3 2 1 2 2
intermetallic compounds
between titanium and 2% Thoriated Tungsten 2.4 2.4 2.4 2.4 2.4 2.4
(mm)
(Kg/s)
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Results of welded sample
Front view Back view
Sample 2
Sample 3
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Results of optical microscopy
Figure.9: SS-Cu boundary (100X) Figure.10: SS-Cu boundary (100X) showing three different
zones
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Results of optical microscopy
Cu
Cu SS 304
Ti
SS 304
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Results of Scanning Electron
Microscopy
300
250
Sample 2
200
Sample 3
150
100
50
0
-4 -3 -2 -1 0 1 2 3 4
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Distance in mm
Results of Tensile Test
4.5
3.5
Load in kN
2.5
Sample 2 Loa
1.5
0.5
0
0 2 4 6 8 10 12
Displacment in mm
Heat input and rate of heat input is revealed to be a very important parameter
during the study. The maximum tensile strength is obtained for the sample which
is welded at higher heat input rate. Samples which are welded at low heat input
did not wet properly the parent metals and which results in very low mechanical
properties.
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Conclusions
Intermetallic phases identified are mainly located at the boundary between the
parent metals and copper.
Tensile strength of the welded sample is quite low compared to the parent metals
and instead of copper, other metals like tantalum, vanadium or sandwich of
tantalum, vanadium and bronze can also be used to achieve better strength.
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Scope of future work
Optimization of parameters with current ampere supply, welding speed and
copper transition metal can be achieved with the aim of achieving higher tensile
strength.
For welding stainless steel to titanium through GTAW welding, a copper filler wire
can be used also instead of a sandwiched setup and to avoid mixing of titanium
and iron, a groove joint can be designed with an overlay of copper material over
stainless steel plate to avoid from mixing to titanium.
Different transition materials like tantalum, vanadium, bronze can be tried which
can result into higher joint strength and better compatibility.
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References
[1] ASM International (1992) ASM handbook: alloy phase diagrams v. 3. ASM International
[2] Poddar D (2009) Solid-state diffusion bonding of commercially pure titanium and precipitation
hardening stainless steel. Int J Recent Trends Eng 1:9399
[3] Kundu S, Chatterjee S (2008) Diffusion bonding between commercially pure titanium and micro-
duplex stainless steel. Mater Sci Eng A 480:316322. doi:10.1016/j.msea.2007.07. 033
[4] Fazel-Najafabadi M, Kashani-Bozorg SF, Zarei-Hanzaki a (2011) Dissimilar lap joining of 304
stainless steel to CP-Ti employing friction stir welding. Mater Des 32:18241832. doi:10.1016/j.
matdes.2010.12.026
[5] Kahraman N, Gulenc B, Findik F (2005) Joining of titanium/ stainless steel by explosive welding
and effect on interface. J Mater Process Technol 169:127133. doi:10.1016/j.jmatprotec.
2005.06.045
[6] Shanmugarajan B, Padmanabham G (2012) Fusion welding studies using laser on TiSS dissimilar
combination. Opt Lasers Eng 50: 16211627. doi:10.1016/j.optlaseng.2012.05.008
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References
[7] Lee JG, Hong SJ, Lee MK, Rhee CK (2009) High strength bonding of titanium to stainless steel
using an Ag interlayer. J Nucl Mater 395:145149. doi:10.1016/j.jnucmat.2009.10.045
[8] Shiue RK, Wu SK, Chan CH, Huang CS (2006) Infrared brazing of Ti-6Al-4V and 17-4 PH stainless
steel with a nickel barrier layer. Metall Mater Trans A 37:22072217. doi:10.1007/BF02586140
[9] Wang T, Zhang B, Chen G et al (2010) Electron beam welding of Ti-15-3 titanium alloy to 304
stainless steel with copper interlayer sheet. Trans Nonferrous Met Soc China 20:18291834. doi:10.
1016/S1003-6326(09)60381-2
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References
[9] Wang T, Zhang B, Chen G et al (2010) Electron beam welding of Ti-15-3 titanium alloy to 304
stainless steel with copper interlayer sheet. Trans Nonferrous Met Soc China 20:18291834. doi:10.
1016/S1003-6326(09)60381-2
[11] Kundu S, Ghosh M, Laik a et al (2005) Diffusion bonding of commercially pure titanium to 304
stainless steel using copper interlayer.MaterSciEngA407:154160.doi:10.1016/j.msea.2005.07.010
[12] BS EN ISO 65071 (2005) Metallic materialsVickers hardness testpart 1: test method. Br
Stand 20
[13] Ppe N, Egerland S, Colegrove P a et al (2011) Measuring the process efficiency of controlled
gas metal arc welding processes. Sci Technol Weld Join 16:412417. doi:10.1179/1362171810Y.
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THANK YOU
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