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.
Similar content being viewed by others
References
P.L. Threadgill: Report 761/2003, TWI, Cambridge, 2003.
2. R.S. Mishra and M.W. Mahoney: Friction stir welding and processing,” ASM Intl. Publisher, Materials Park, OH, 2007, pp. 8-12.
3. J. Barry, G. Akdogan, R. Smyth, F. McAvinue and P. O’Halloran: Industrial Diamond Review, 2006, vol. 66, no. 3, pp. 46-53.
4. T.K. Harris, E.J. Brookes and C.J. Taylor: Intl J. Refractory Metals & Hard Materials, 2001, vol. 19, no. 4-6, pp. 267-273.
5. Z. Iqbal, N. Saheb and A.R. Shuaib: J. Alloys & Compounds, 2016, vol. 674, pp. 189-199.
6. B. Thompson and S.S. Babu: Welding Journal, 2010, vol. 89, pp. 256s–261s.
7. P.N. Browning, S. Alagic, A. Kulkarni, L. Matson and J. Singh: MSEA, 2016, vol. A674, pp. 701-712.
8. O. El-Atwani, D.V. Quach, M. Efe, P.R. Cantwell, B. Heim, B. Schultz, E.A. Stach, J.R. Groza and J.P. Allain: MSEA, 2011, vol. A528, pp. 5670-5677.
W.D. Klopp: Report No 4955, NASA Lewis Research Center, Cleveland OH, 1968.
M. Dickinson: Trans. Am. Soc. Met., 1959, vol. 51, pp. 758–771.
11 C.T. Sims and RI. Jaffee: Trans. ASM, 1960, vol. 52, pp. 929-941.
W.D. Klopp, W.R Witzke and P.L. Raffo: Report no 3483. NASA Lewis Research Center, Cleveland, OH, 1966.
13. P.L. Raffo: J. Less-Common Metals, 1969, vol. 17, pp. 133-143.
L.S. Rubenstein: Report no 4379, NASA Lewis Research Center, Cleveland, OH, 1968.
W.D. Klopp and W.R Witzke (1969) Report 5348. NASA Lewis Research Center, Cleveland, OH.
D. Klopp, P.L. Raffo, W.R. Witzke (1971) J. Org. Met. 6:27-38.
W.D. Klopp and W.R Witzke (1971) J. Less Common Met., 24:427-443.
18. D. Lee, M.A. Umer, H.J. Ryu and S.H. Hong: Int. J. Refract. Met. Hard Mater., 2014, vol. 44, pp. 49-53.
19. A. Luo, K.S. Shin and D.I. Jacobson: Acta Metall. Mater., 1992, vol. 40, pp. 2225-2232.
20. A. Luo, D.I. Jacobson and K.S. Shin: Scripta Metall. Mater., 1989, vol. 23, pp. 397-400.
D. Lee, M.A. Ulmer, H.J. Ryu and S.H. Hong: Int. J. Refract. Met. Hard Mater., 2014, vol. 44, pp. 49-53.
22. T.B. Massalski: Binary Alloy Phase Diagrams, ASM Intl. Publisher, Materials Park, OH, 1990.
B.D. Bryskin and J.-C. Carlén: Proc. 127th TMS Annual Meeting & Exhibition, San Antonio, TX, 1998.
B.D. Bryskin and J.-C. Carlén: Matls. & Mfg. Proc., 1996, vol. 11/1, pp. 67–81.
25. R.M. German: Sintering: Powder metallurgy Science, Metal Powder Industries Federation Pub., Princeton, NJ, 1984, pp. 145-200.
26. E.Y. Ivanov, C. Suryanarayana and B.D. Bryskin: MSEA, 1998, vol. A251, pp. 255-261.
27. F.H. Froes, B.D. Bryskin, C.R. Clark, C. Suryanarayana and E.G. Baburaj: Rhenium and Rhenium alloys, TMS Publisher, Warrendale, PA, 1997, pp. 569-583.
E. Ivanov and C. Wickersham: Proc. Intl. Plansee Seminar, Austria Publisher, Reutte, 1997, vol. 1, pp. 207–216.
29. M.S. Boldrick, E. Yang and C.N.J. Wagner: J. Non-Cryst. Solids, 1992, vol. 150, pp. 478-482.
I. Charit: Nuclear Energy University Project No. 09-775, Final Report CFP-09-775, DOE Publisher, New York, 2012.
31. G. Lee, J. McKittrick, E. Ivanov and E.A. Olevsky: Int. J. Refract. Met. Hard Mater., 2016, vol. 61, p. 22-29.
32. N.C. Kothari: J. Less-Common Met. 1963, vol 5, pp. 140-150.
33. T. Vasilos and J.T. Smoth: J. Appl. Phys., 1964, vol. 35, pp. 215-217.
34. Z. Gao, G. Viola, B. Milsom, I. Whitaker, H. Yan and M. Reece: MMTB, 2012, vol. 43, pp. 1608-1614.
35. Q. Wei, T. Jiao, K.T. Ramesh, E. Ma, L.J. Kecskes, L. Magness, R. Dowding, V.U. Kazykhanov, R.Z. Valiev: Acta Mater., 2006, vol. 54, pp. 77-87.
36. Q. Wei, H.T. Zhang, B.E. Schusterb, K.T. Ramesh, R.Z. Valiev, L.J. Kecskes, R.J. Dowding, L. Magness and K. Cho: Acta Mater., 2006, vol. 54, pp. 4079-4089.
37. F. V. Lenel: JOM, 1955, vol. 7, pp. 158-167.
J. R. Groza: AM Metals Handbook, Powder Metal Technologies & Applications, Vol. 7, ASM International, Materials Park, OH, 1998, pp. 583–589.
39. J.R. Groza and A. Zavaliangos: MSEA, 2000, vol. A287, pp. 171-177.
40. J.R. Groza, M. Garcia and J.A. Schneider: J. Mat. Res., 2001, vol. 16/1, pp. 286-292.
41. R. Orru, R. Licheri, A.M. Locci, A. Cincotti and G. Cao: Mat. Sci. & Engr. R., 2009, vol. 63, pp. 127-287.
42. Z.A. Munir, D.V. Quach and M. Ohyanagi: J. Am. Ceram. Soc., 2011, vol. 94/1, pp. 1-19.
K.C. Cho, R.H. Woodman, B.R. Koltz, and R.J. Dowding: Matls & Mfgt Proc., 2004, vol. 19/4, pp. 619–30.
44. M. Yao, Z. Zhangjian, T. Jun and L. Ming: Rare Metal Matl. & Engr., 2011, vol. 40, pp. 4-8.
45. J. Choi, H-M. Sung, K-B. Roh, S-H. Hong, G-H. Kim and H.N. Han: Int. J. Refract. Met. Hard Mater., 2017, vol. 69, pp. 164-169.
T. Ryu, K.S. Huang, Y.J. Choi and H.Y. Sohn: Intl. J. Refract. Met. Hard Mater, 2009, vol. 27, pp. 701-704.
47. Z. Gao, G. Viola, B. Milsom, I. Whitaker, H. Yan and M.J. Reece: MMTB, 2012, vol. 43, pp. 1608-1614.
48. N. Van Minh, G. Karunakaran and Y. Konyukhv: J. Clust. Sci., 2017, vol. 28, p. 2905-2917.
49. W. Song and X. Ming: Applied Mech. & Matl., 2012, vol. 236-237, p. 113-117.
50. A. Monda, A. Upadhyaya and D. Agrawal: Int. J. Refract. Met. Hard Mater., 2010, vol. 28, pp. 597-600.
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.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Manuscript submitted June 14, 2019.
Rights and permissions
About this article
Cite this article
Schneider, J., Terrell, J., Farris, L. et al. Low-Cost Fabrication of Tungsten-Rhenium Alloys for Friction Stir Welding Applications. Metall Mater Trans B 51, 35–44 (2020). https://doi.org/10.1007/s11663-019-01726-6
Received:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11663-019-01726-6