Friction push plug welding in airframe structures using Ti-6Al-4V plug

Abstract

Friction push plug welding, a recent variation of friction welding process has tremendous applications in joining and repairing operations in aerospace and automotive engineering. The main objective of the present work demonstrates joining feasibility of high performance Ti-6Al-4V to low density AA2024 employed in passenger seat track, vertical stabilizers and wing spars of aircraft structures of aerospace applications. Mechanical testing is carried out to analyse the joint integrity and strength of Ti-6Al-4V/AA2024 joints. The microstructural aspects are investigated to study the bonding mechanism to obtain defect-free welds. SEM micrograph reveals the formation of different zones with significant reduction in grain size. EDX analysis confirms the formation of Ti3Al intermetallic compound which is less brittle. Appreciable impact strength of about 286.354 kJ/m2 indicates friction push plug welding as a promising candidate for joining of Ti-6Al-4V and AA2024 in airframe structures.