Microstructural characterization and formation of α′ martensite phase in Ti–6Al–4V alloy butt joints produced by friction stir and gas tungsten arc welding processes

The obtained microstructures of a Ti–6Al–4V alloy welded by Gas Tungsten Arc Welding (GTAW) and Friction Stir Welding (FSW) were investigated and evaluated quantitatively. In the GTAW method, the effect of current was examined so that the samples were subjected to various currents between 90 and 120 A. In the FSW process, samples were welded by different rotational speeds (450–850 rpm). Non-destructive tests including Visual and Radiography Tests (VT and RT) were used to identify defect-free samples. The microstructural studies by electron microscopes revealed formation of different phases in the weld area of the samples welded via mentioned methods. The recorded peak temperatures in the weld regions compared favorably with the expectations about the evolved microstructures. A bi-modal microstructure was just obtained in the FSWed sample with a peak temperature below β transus temperature (T < 995 °C). α′ martensite phase, which is an acicular and strengthening phase in this alloy, was only observed in FSWed specimens.

► A fusion (GTAW) and a solid state method (FSW) are used to weld Ti–6Al–4V alloy.
► Optimal parameters yielding defects-free weldments are identified.
► A very careful microstructural quantification of the FSW and GTAW weldments are performed.
► α′ Martensite formed only in FSWed samples and avoided in GTAWed samples.
► FSW process produced joints with considerably smaller HAZ and higher hardness values.