Interfacial Microstructure and Formation of Direct Laser Welded CFRP/Ti-6Al-4V Joint

Joining fiber reinforced polyether ether ketone resin matrix composite (PEEK-CFRP) with Ti-6Al-4V titanium alloy to form a composite structure is a promising manufacturing process. Huge difference of material properties is the biggies challenge to join them. Continuous laser welding process is conducted in this experiment to join the two materials. In this study, joints under different welding speeds were obtained. Mechanical properties and microstructures were observed, and the interfacial structures were tested. The results showed that fixed joint could be obtained. As the welding speed decreased, the tensile shear first increased and then decreased. The shear force reached a maximum value of 36.8 N/mm at the speed of 10 mm/s. The quality of joint could be observably affected by welding speed. The formation of bubbles, cracks, and anchor effect at the interface were the main factors affecting the mechanical property of joint. Thus, adhesion failure was the main failure form for CFRP fracture. Ti, Al and some other elements had been diffused across the interface, resulting in the formation of intermediate transition layer. The result of EDS, X-ray and XPS test indicated that CTi0.42V1.58 phase could be formed, and Ti at the interface could react with the oxygen and carbon of CFRP to form TiO2, TiO and TiC, forming a stable joint structure.

Automated summary

The combination of PEEK-CFRP with Ti-6Al-4V titanium alloy using continuous laser welding process is a promising manufacturing method, resulting in strong joints. However, the quality of joints is significantly affected by welding speed, with the formation of bubbles, cracks, and anchor effects impacting mechanical properties.