Influence of Filler on the Microstructure, Mechanical Properties and Residual Stresses in TIG Weldments of Dissimilar Titanium Alloys

The influence of titanium alloy (Ti–5Al–2.5Sn) and commercially pure titanium (cpTi) as fillers on dissimilar pulsed tungsten inert gas weldments of Ti–5Al–2.5Sn/cpTi was investigated in terms of microstructure, mechanical/nano-mechanical properties, and residual stresses. A partial martensitic transformation was observed in the weldments for all the welding conditions due to high heat input. The microstructure evolved in the FZ/cpTi interfacial region was observed to be the most sensitive to the proportion of α stabilizer in the filler alloy. Furthermore, the addition of filler alloy improved the tensile properties and nano-mechanical response of the weld joint owing to the increased volume of metal in the weld joint. As compared to the Ti–5Al–2.5Sn wire, the use of cpTi filler wire proved to be better in terms of energy absorbed during tensile and impact tests, tensile strength and ductility of the dissimilar welds. An asymmetrical residual stresses profile was observed close to the weld centerline, with high compressive stresses on the Ti–5Al–2.5Sn side for both the weldments obtained with and without filler wires. This was attributed to mainly the low thermal conductivity of Ti–5Al–2.5Sn. The presence of residual stresses also influenced the nano-hardness profile across the weldments.