REGULARITIES OF DEFECTS AND STRUCTURAL INHOMOGENEITIES FORMATION DURING FRICTION STIR PROCESSING OF TITANIUM ALLOY PRODUCTS OBTAINED BY WIRE-FEED ELECTRON BEAM ADDITIVE MANUFACTURING

The paper studies the regularities of structure formation in samples of titanium alloy Ti–4Al–3V obtained by additive wire-feed electron beam additive manufacturing and undergone to friction stir processing. The studies conducted show that during the processing there is an intensive interaction between the tool and the material, which leads to significant changes in the structure of the stir zone. The interaction between the nickel-base superalloy tool and the material is of an adhesive, mechanical, thermal and diffusion nature. Its characteristics determine the formation of the structure and material properties of the stir zone and, consequently, of the obtained parts. For this reason, in this study, the main defects and inhomogeneities formed in the stirred zone of the samples have been considered in comparison with the processes occurring in the area of contact between the tool and the material. The main changes in the structure of the titanium alloy Ti–4Al–3V after friction stir processing, caused by its interaction with the nickel tool, are formed in the areas of the stir zone with a composite structure with a high local volume fraction of intermetallic phases. During processing, the tool can be excessively penetrated in the material in such a way that it touches the substrate in the lower part of the plate. Even a slight penetration of the tool into the substrate leads to the penetration of steel particles into the stir zone due to the vertical flow of material in the stir zone. The described changes with the formation of a number of inhomogeneities and defects in the structure after processing lead to a decrease in the plasticity and strength of the samples in comparison with the material with a defect-free structure.

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