Defect Repair Process for Butt Welds of Small Diameter TA16 Ti Alloy Pipes

CHEN Kun; XU Shaofeng; PAN Xiaodong; WANG Jian

doi:10.7512/j.issn.1001-2303.2025.06.17

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Defect Repair Process for Butt Welds of Small Diameter TA16 Ti Alloy Pipes
Vol. 55, Issue 6, Pages: 125-131(2025)
Received：27 April 2025，

Revised：16 May 2025，

Published：20 June 2025
DOI： 10.7512/j.issn.1001-2303.2025.06.17
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陈坤，徐少峰，潘晓冬，等.小径TA16钛合金管对接焊缝的缺陷修复工艺研究［J］.电焊机，2025，55（6）：125-131. DOI： 10.7512/j.issn.1001-2303.2025.06.17.

CHEN Kun, XU Shaofeng, PAN Xiaodong, et al.Defect Repair Process for Butt Welds of Small Diameter TA16 Ti Alloy Pipes[J].Electric Welding Machine, 2025, 55(6): 125-131. DOI： 10.7512/j.issn.1001-2303.2025.06.17.

摘要

针对小径TA16钛合金管对接焊缝气孔缺陷修复难题，提出一种基于机械加工与有限元模拟协同优化的缺陷返修工艺。通过射线检测与金相解剖分析，发现气孔缺陷主要分布于焊缝中心区（深度为焊缝厚度的1/2~1/3），据此设计特定尺寸的机械加工返工坡口。采用Abaqus软件建立三维热-力耦合模型，通过双椭球热源校核与温度场动态模拟，揭示了返工焊接过程中熔池演化规律及管内壁热循环特性，明确了峰值电流35 A、基值电流30 A的梯度调控参数可实现返工坡口根部精准熔透且内凸可控。基于优化参数对15条含缺陷焊缝实施补焊，结果表明：修复后焊缝气孔缺陷完全消除，微观组织中热影响区未显著扩宽，焊缝中心区因完全重熔形成长宽比大的片层状α相组织；室温及350 ℃高温抗拉强度分别达567 MPa与368 MPa，均高于母材标准值，断裂位置均位于母材区域，证明该工艺可以用于小径TA16钛合金管对接焊缝的缺陷修复。

Abstract

To address the challenges in repairing porosity defects in butt welds of small-diameter TA16 titanium alloy tubes

a defect rework process synergistically optimized through mechanical machining and finite element simulation is proposed. Radiographic testing and metallographic dissection revealed that porosity defects primarily concentrate in the central weld zone (at depths of ½ to ⅔ of the weld thickness). Based on this finding

a rework groove with specific dimensions was designed via mechanical machining. A three-dimensional thermo-mechanical coupling model was established using Abaqus software

incorporating dual-ellipsoid heat source calibration and dynamic temperature field simulation. This approach elucidated the molten pool evolution and internal wall thermal cycling characteristics during rework welding

identifying gradient-controlled parameters (peak current: 35 A

base current: 30 A) to achieve precise root penetration and controllable internal convexity. Repair welding trials on 15 defective welds using optimized parameters demonstrated complete elimination of porosity defects. Microstructural analysis revealed no significant broadening of the heat-affected zone

while fully remelted weld centers exhibited lamellar α-phase structures with high aspect ratios. The repaired welds exhibited room-temperature and 350℃ high-temperature tensile strengths of 567 MPa and 368 MPa

respectively

both exceeding base material specifications

with fractures occurring in the parent material zone

confirming no mechanical degradation induced by the repair process. This study establishes a process optimization framework for defect repair in thin-walled titanium alloy tubes

offering significant engineering value for enhancing the reliability of titanium components in aerospace and related fields.

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references

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