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<p>Developing the next-generation aero engines requires components with excellent high-temperature capabilities that can withstand extreme operating conditions, pushing the limits of current material combinations to fabricate integral rotors and disc shafts. Herein, an engineering strategy to tailor the weld interface by controlling the extent of weld axial upset was employed to design novel FGH4108/GH4065A dissimilar superalloy joints via inertia friction welding (IFW). Comprehensive microstructural characterization and distribution of strengthening phases in IFWed joints were described both at low and high axial upset. Solid solution strengthening at the interface occurred due to the dissolution of γ′ strengthening phase, where the distortion of the matrix lattice hindered the movement of dislocations. Incomplete dynamic recrystallization at low axial upset induced the accumulation of deformed grains at interface, resulting in intense stress–strain concentration and likelihood of crack formation. Considerable dislocation density remained in weld zone at high axial upset, demonstrating that the dislocation density after dynamic recrystallization was lower than that generated by intense deformation. The ultimate tensile strength reached 1426&#xa0;MPa with an elongation of 14.2% at high axial upset, increased by 5.5% and 19.3% relative to low axial upset, respectively. Fracture initiated on FGH4108 side and crossed the interface to the GH4065A side at low axial upset, while the FGH4108/GH4065A joint failed at base material of GH4065A side with noticeable necking with large upsets. Interface engineering enabled by regulating axial upsets provided a new theoretical basis for the empirical parameters, guiding future studies for high-performance IFW of newly developed dissimilar superalloys.</p>

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Axial upset driven inertia friction welding of FGH4108/GH4065A dissimilar superalloys

  • 期刊论文

  • 发表日期：

    2026年6月22日

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  • Qiang Zhao,
  • Zhiwei Qin,
  • Yongxian Huang,
  • Peng Li,
  • Zhijie Ding,
  • Liangliang Zhang,
  • Yutao Sun,
  • Jiachen Li,
  • Jiantao Liu,
  • Qiang Zhang,
  • Yixing Wang,
  • Honggang Dong

摘要

Developing the next-generation aero engines requires components with excellent high-temperature capabilities that can withstand extreme operating conditions, pushing the limits of current material combinations to fabricate integral rotors and disc shafts. Herein, an engineering strategy to tailor the weld interface by controlling the extent of weld axial upset was employed to design novel FGH4108/GH4065A dissimilar superalloy joints via inertia friction welding (IFW). Comprehensive microstructural characterization and distribution of strengthening phases in IFWed joints were described both at low and high axial upset. Solid solution strengthening at the interface occurred due to the dissolution of γ′ strengthening phase, where the distortion of the matrix lattice hindered the movement of dislocations. Incomplete dynamic recrystallization at low axial upset induced the accumulation of deformed grains at interface, resulting in intense stress–strain concentration and likelihood of crack formation. Considerable dislocation density remained in weld zone at high axial upset, demonstrating that the dislocation density after dynamic recrystallization was lower than that generated by intense deformation. The ultimate tensile strength reached 1426 MPa with an elongation of 14.2% at high axial upset, increased by 5.5% and 19.3% relative to low axial upset, respectively. Fracture initiated on FGH4108 side and crossed the interface to the GH4065A side at low axial upset, while the FGH4108/GH4065A joint failed at base material of GH4065A side with noticeable necking with large upsets. Interface engineering enabled by regulating axial upsets provided a new theoretical basis for the empirical parameters, guiding future studies for high-performance IFW of newly developed dissimilar superalloys.