Abstract
The present study considers the effect of strength mismatch on the fracture behaviour of diffusion bonded joints between commercially pure (CP) Ti and Ti-6Al-4V (Ti64), including dissimilar joints and sandwich structures with strength undermatching and overmatching. The aim of the investigation is to determine the influence of the interlayer thickness (for both higher and lower strength interlayers) and the bond quality on the deformation behaviour and fracture toughness of the joints. The influence of mechanical heterogeneity (strength mismatch) on the fracture behaviour of the interface in dissimilar joints was also investigated. Round bars of CP Ti and Ti64 having a diameter of 40 mm were diffusion bonded as dissimilar butt joints and sandwich structures containing lower strength (undermatching) and higher strength (overmatching) interlayers of different thicknesses. Round transverse tensile specimens and standard four point bend (single edge notch bend) specimens were extracted from the joints via spark erosion cutting. The four point bend specimens were fatigue precracked to introduce a sharp crack after introducing machine notches at the centre of the interlayers in the sandwich structures and at the interface in the dissimilar joints, and tested at room temperature. Some specimens were also prepared with the crack positioned away from the interface to determine the effect of notch position on fracture behaviour. The effect of strength mismatch on the crack tip opening displacement fracture toughness parameter of the joints has been evaluated. Crack initiation, crack growth, and crack deviation processes have been examined and fracture resistance curves (R curves) constructed for the joints. These results were used to explain the influence of mechanical heterogeneity of the joints and interlayer thickness on fracture behaviour.
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