FEATURES OF INTERACTION BETWEEN TOOL MADE OF ZHS6U ALLOY AND ADDITIVELY PRODUCED TITANIUM ALLOY DURING FRICTION STIR PROCESSING

In the work the characteristics of interaction of titanium alloy Ti‒6Al‒4V, substrate from stainless steel SS321 and tool from nickel-based superalloy ZhS6U at friction stir processing are studied. It is shown that the mechanism of tool-material interaction during friction stir processing can undergo significant changes due to the penetration of a second material into the contact zone. The basic sequence of tool wear process in the form of gradual formation of tribological layer from mechanical mixture of intermetallic phases and carbides is preserved, but the wear intensity increases. It was found that even a small excessive penetration of the tool pin into the substrate leads to stirring of its fragments into the workpiece material, which changes the process of flow and metal transfer along the tool contour.  Studies using the technique of quick stopping the processing with cutting out the area with the tool penetrated into the workpiece allowed us to determine how tool and substrate fragments are penetrated into the workpiece material. It was found that the substrate material is penetrated into the stir zone by the formation of narrow streams along the contour of the tool with a pronounced vertical orientation. The penetration of tool fragments into the material of the stir zone occurs continuously during the processing, showing the realization of both laminar and vortex metal flows. The interaction between the metal flows of the titanium alloy and the flows from the substrate has a complex and heterogeneous character and is related to the pressure exerted by the tool on the workpiece due to the clamping force and the force resisting the longitudinal movement of the tool.

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