Application of the theory of critical distance technique to predict fracture toughness in friction stir welded Ti-6Al-4V sheet

With modern day socioeconomic pressures to deliver more cost effective, higher performance and energy efficient mechanisms and structures, light weight design is coming more to the forefront of design methodologies. These methodologies need to apply lightweight materials in unison with a defect tolerant design strategy. Titanium is certainly not a new material and was used in large quantities in the 1960’s and ‘70s, but mostly in military applications. The main drawback of this material was cost, however due to current design needs as mentioned the consumption of the material is rising rapidly. Friction stir welding is by no means a new technique anymore, however, relatively speaking it is still in its infancy when compared to other traditional welding techniques. It has been applied mostly to low melting temperature metals, more specifically aluminium; however, its application to higher melting temperatures has started to enjoy more attention over the last few years. The lower temperatures at which the weld occurs, when compared to conventional processes, is the main reason for applying this technique to materials melting at a higher temperature such as titanium. Fracture mechanics allows modern-day designers and maintenance engineers to operate structures with an inherent flaw. These flaws may be due to geometric features of the design; fabrication defects or defects such as cracks that have developed over time within an operational structure. Fracture mechanics has evolved significantly since Griffith first proposed it in the early 20th century. The application of the method is often complex and determining the material properties for fracture resistance can be problematic and costly. Many techniques have been proposed over time to simplify the application of this method and one of these techniques would be the theory of critical distance. Since the technique is relatively new and has mostly been applied to more brittle materials, this study aimed not only to apply this technique to a more ductile material but additionally to one that is classified as a sheet material. The initial tests of this study investigated if a common convergent point could be determined by using three notches varying in size. The technique does not have a standard that governs its application. The initial tests did not yield a common intersecting point thus a second study was applied to see if sample width would influence the results. The results from the study indicated that wider samples seemed to yield similar apparent fracture toughness results, however a common convergence point could still not be established. This prompted a more in-depth study which involved various sample widths coupled with varying notch depths. Sharper notches were also applied and samples with controlled cracks were also tested. The results clearly showed that as the plastic zone size increases in relation to the ligament length of the sample, the critical distance becomes larger. The results also suggested that it would perhaps be best to use sample sizes with notches which allow fracture of the sample before the nett section stress reaches the material’s yield strength. The final tests involved testing the friction stir welded material. Various other studies were also done to corroborate the fracture toughness results. The stress relieved samples showed a reduction in the fracture toughness due to possible precipitation hardening during the stress relieving heat treatment process. The welded material showed an increase in the apparent fracture toughness when compared to the parent plate. The results indicate that residual stresses have an influence on the fracture toughness. In terms of the critical distance, it would appear that the value stays unchanged from the parent plate to the welded material; however, what is significant was that the value seemed to stay more or less constant as long as the nett section stress of the notched samples stayed below the yield stress of the material