Search

The assessment of fatigue is a crucial concern in welded components and structures. This study investigates the fatigue properties and models for predicting fatigue crack growth in Ti-6Al-4V titanium alloy when processed by vacuum brazing with TiCuNi filler. Fatigue properties and the impact of the stress ratio were determined through constant amplitude fatigue tests. By utilizing the results obtained from variable amplitude fatigue tests, various prediction models for fatigue crack growth were examined: modifications for load interaction, residual stress, and crack closure. The results indicate that the microstructures in the brazed zone consist of numerous fine, elongated needle-like Widmanstätten structures. In terms of cycle counting methods, the rainflow method outperforms the simple-range method. In the stable crack growth rate region, fatigue crack growth rate increases with the rise in stress ratio in a manner similar to high-strength steels. The Paris model without any modification obtains good predictions. For models modified with crack closure, the Elber model yields slightly better prediction results than the Schijve model. Among fatigue crack growth prediction models, the Willenborg model with residual stress modification produces the best results. Fracture surfaces within fatigued specimens’ brazed zones exhibit ductile failure characteristics, where fatigue striations and secondary cracks were observed.

In this study, the optimal parameters of the vacuum brazing titanium alloy Ti-6Al-4V with TiCuNi filler (30 μm-thick metal foil) were investigated by the Taguchi method. The microstructures, microhardness, and fractographs of the titanium brazed joints produced by these optimal parameters were also analyzed. The results of this study demonstrate that for the best tensile strength, the optimal combination of process parameters is: 890 °C soaking temperature, 60 min soaking time, 975 °C brazing temperature, and 45 min brazing time. The tensile strength obtained by welding with the optimal parameters was found to be 1265 MPa. A small error of 0.24% between experimental and predicted values confirmed the validity of the combined optimized parameters. Finally, from the means of variance analysis (ANOVA), out of the four factors, the highest contribution to the optimal parameters was found to be the brazing time, accounting for 47.3%. The base material of vacuum brazing (VB) weldment is mainly composed of white granular α titanium, slender β titanium, and layered structures that are interlaced by α and β. The weld bead, composed of Ti-15Cu-15Ni, contains many slender needle-shaped Widmanstätten structures. This structure is associated with higher strength and lower ductility. The weld bead hardness of the vacuum brazed parts is higher than that of laser beam weldment and gas tungsten arc weldment. This study demonstrates the feasibility of the Taguchi method for obtaining the optimal process parameters of titanium vacuum brazed joints.