Effect of Preheating on the Inertia Friction Welding of the Dissimilar Superalloys Mar-M247 and LSHR

Differences in the elevated temperature mechanical properties of cast Mar-M247 and forged LSHR make it difficult to produce sound joints of these alloys by inertia friction welding (IFW). While extensive plastic upset occurs on the LSHR side, only a small upset is typically developed on the Mar-M247 side. The limited plastic flow of Mar-M247 thus restricts the extent of “self-cleaning” and mechanical mixing of the mating surfaces, so that defects remain at the bond line after welding. In the present work, the effect of local preheating of Mar-M247 immediately prior to IFW on the welding behavior of Mar-M247/LSHR couples was determined. An increase in the preheat temperature enhanced the plastic flow of Mar-M247 during IFW, which resulted in extensive mechanical mixing with LSHR at the weld interface, the formation of extensive flash on both the Mar-M247 and LSHR sides, and a sound bond. Performed in parallel with the experimental work, finite-element-method (FEM) simulations showed that higher temperatures are achieved within the preheated sample during IFW relative to its non-preheated counterpart, and plastic flow is thus facilitated within it. Microstructure and post-weld mechanical properties of the welded samples were also established.