About this Abstract |
| Meeting |
2026 AWS Professional Program
|
| Symposium
|
2026 AWS Professional Program
|
| Presentation Title |
Cold spray deposition for fabrication of interlayers in stainless steel – titanium dissimilar metal laser welding |
| Author(s) |
Erin Barrick, Leah Mills, Michael Kracum, Joseph Padilla, Landon Schnebly, Austin Pisani, Daniel Leseberg, Jack Herrmann |
| On-Site Speaker (Planned) |
Erin Barrick |
| Abstract Scope |
Dissimilar metal laser welding of stainless steel (SS) to titanium alloys remains one of the most challenging combinations because when directly joined, brittle intermetallic phases form in the fusion zone, compromising the integrity of the joint. We have addressed this issue by applying interlayers using the cold spray (CS) deposition technique. CS is a solid-state deposition process, therefore there is no melting at the interface, enabling a wide variety of alloys for interlayer use. In this work, the CS interlayer was one of the two alloys in the dissimilar combination (i.e., a third dissimilar interlayer was not used): 304L SS was cold sprayed onto Ti-6Al-4V to form a 304L interlayer that was laser welded to 304L sheet; the reverse was also investigated where Ti-6Al-4V was cold sprayed onto 304L SS and the Ti-6Al-4V interlayer was laser welded to Ti-6Al-4V. Different CS processing conditions and post-CS annealing treatments were utilized to influence 1) adhesion of CS interlayer to substrate, 2) density of CS interlayer, and 3) post-CS laser weldability. A wide range of laser welding parameters were explored, including continuous wave and pulse laser welding, to understand processing windows. Microstructure characterization was performed using light optical and scanning electron microscopy. The spatial mechanical properties across the entire dissimilar joints were characterized with microhardness and select interfaces were further characterized with nanoindentation. Overall, many dissimilar welds are defect free; initial high-temperature post-CS annealing treatments promoted diffusion at the CS solid-state interface resulting in interlayer delamination during laser welding. Subsequent annealing times/temperatures were selected to minimize diffusion while facilitating stress relief in the interlayer. These results are significant in that CS is a promising process for facilitating dissimilar joints with careful selection of processing parameters for both CS and laser welding.
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| Proceedings Inclusion? |
Undecided |