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Low-Cost Fabrication of Tungsten-Rhenium Alloys for Friction Stir Welding Applications

  • Judy SchneiderEmail author
  • Jordan Terrell
  • Laura Farris
  • Dennis Tucker
  • Todd Leonhardt
  • Hennig Goldbeck
Article
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Abstract

Friction stir welding (FSW) of high-melting temperature alloys, such as steel and Inconel, requires tooling that can survive under the applied loads at the elevated temperatures. Tungsten-Rhenium (W-Re) alloys are a suitable candidate for this application; however, the costs typically associated with achieving the required densities and grain structure for the tooling are high due to the lengthy traditional processing required. Further costs are incurred in machining the starting bar stock to the final FSW tooling configuration. An alternate processing method is used in this study to shorten the fabrication time using direct current sintering which rapidly consolidates the starting powders at lower temperatures than used in traditional powder metallurgy. Although this process enables retention of the fine grain size, the sintering time is too short to form the desired single, solid phase. Therefore, the specimens were subjected to a post-consolidation heat treatment to fully solutionize the W matrix. Once the desired density and solid solution phase was verified in coupons, the final processing parameters were used to consolidate a net shape tool for FSW.

Notes

Acknowledgments

The authors (JAS, JT, LF) gratefully acknowledge the funding support provided by NASA-MSFC Cooperative Agreement for Dual Use Technology Development, Grant No. 80MSFC17M0008. All powders and their preparation used in this study were provided by Re Alloys.

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Copyright information

© The Minerals, Metals & Materials Society and ASM International 2019

Authors and Affiliations

  • Judy Schneider
    • 1
    Email author
  • Jordan Terrell
    • 1
  • Laura Farris
    • 1
  • Dennis Tucker
    • 2
  • Todd Leonhardt
    • 3
  • Hennig Goldbeck
    • 4
  1. 1.Department of Mechanical and Aerospace EngineeringUniversity of Alabama in HuntsvilleHuntsvilleUSA
  2. 2.National Aeronautics and Space Administration, Marshall Space Flight CenterHuntsvilleUSA
  3. 3.Rhenium AlloysNorth RidgevilleUSA
  4. 4.Bundesanstalt für Materialforschung und -prüfungBerlinGermany

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