Abstract
The weld defects are a constant problem to mechanical components of various applications. Defects may be the root cause of constant failure to critical components and may further create unsafe work environment in industries. Although friction welding process is a solid state welding technique, it is also susceptible to weld defects. The rotary friction welding of titanium alloy Ti-6Al-4V was conducted to investigate the formation of weld defects and their types. The microstructure analysis and visual inspection of weld joints was done to identify defects present in the welds of different welding parameters. Mechanical tests were also conducted to investigate the effect of defects in the properties of the weld joints. The common defects in rotary friction welding were observed. Flaws such as voids, excessive flash and discolouration were identified during the study and were linked to the unsuitable welding conditions. The tests conducted revealed that defects have a negative impact on the properties and quality of the weld joint. The relationship between defect and weld condition was studied. The study revealed that majority of the defects exist due to unsuitable combination of welding parameters utilised. Therefore, this paper presents the study of defects formation in the friction welding process of titanium alloy Ti-6Al-4V.