Interfacial Bonding Behavior of IMI834/Ti6246 Dual Alloy Joints Prepared by Inertial Friction Welding

ZHA Xiaohui; FENG Kaikai; SHI Shanguang; YANG Yuchen; LU Zelun; ZENG Xinyun; CAO Sheng; ZHAO Zhanglong

doi:10.3969/j.issn.1674-6457.2026.05.005

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (5) : 49-60. DOI: 10.3969/j.issn.1674-6457.2026.05.005

Additive Manufacturing

Interfacial Bonding Behavior of IMI834/Ti6246 Dual Alloy Joints Prepared by Inertial Friction Welding

ZHA Xiaohui^1,2, FENG Kaikai¹, SHI Shanguang^1,3,*, YANG Yuchen¹, LU Zelun⁴, ZENG Xinyun¹, CAO Sheng⁵, ZHAO Zhanglong⁵

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Abstract

To meet the joining requirement of dissimilar materials for aero-engine compressor disks, the work aims to investigate the dynamic evolution law of the interfacial microstructure during inertia friction welding (IFW) of IMI834 near-α titanium alloy and Ti6246 near-β titanium alloy, and reveal the bonding mechanism of the synergistic evolution of dynamic recrystallization (DRX), grain growth, and phase transformation at the interface of dissimilar titanium alloy joints. IFW was employed to realize the conical joint formation of IMI834 high-temperature titanium alloy and Ti6246 high-strength titanium alloy. The microstructure evolution of the joint at different stages and the interfacial bonding mechanism were characterized via optical microscope (OM) and scanning electron microscope (SEM). The interfacial temperature of the two alloys rose rapidly above the β-phase transformation point under the thermomechanical coupling induced by friction at the initial stage of joint formation. The original α-phase fully transformed into β-phase under the impact of severe thermoplastic deformation and DRX. A staggered lamellar α-phase developed on the IMI834 alloy side, whereas a metastable β-grain structure within a significant accumulation of dislocation density formed on the Ti6246 alloy side owing to its higher content of β-stabilizing elements. In the bonding stage, the lamellar α-phase on the IMI834 side underwent coarsening, and the β-grains on the Ti6246 side grew along with the precipitation of acicular α-phase. Electron backscatter diffraction (EBSD) analysis revealed that the recrystallized grains grew across the interface on both sides which achieved interfacial metallurgical bonding of the alloys under the combined action of high temperature and high pressure. The dynamic evolution mechanism of interfacial bonding during the IFW process of IMI834/Ti6246 dissimilar alloys is clarified, which proceeds in the sequence of thermoplastic deformation → DRX → grain boundary migration → α-phase precipitation, providing a theoretical foundation for the reliable joining of dissimilar titanium alloy components in aero-engines.

Key words

titanium alloy / inertia friction welding / dynamic recrystallization / intergrowth grain / interfacial bonding

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ZHA Xiaohui, FENG Kaikai, SHI Shanguang, YANG Yuchen, LU Zelun, ZENG Xinyun, CAO Sheng, ZHAO Zhanglong. Interfacial Bonding Behavior of IMI834/Ti6246 Dual Alloy Joints Prepared by Inertial Friction Welding[J]. Journal of Netshape Forming Engineering. 2026, 18(5): 49-60 https://doi.org/10.3969/j.issn.1674-6457.2026.05.005

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