Fatigue in laser welded titanium tubes intended for use in aircraft pneumatic systems

Abstract The pneumatic system conducts the pressurized hot air from the engine to the environmental systems of the aircrafts. In-service failures of arc-welded pneumatic parts have driven further developments of laser beam welding as an alternative method. Here, a fiber laser with 2 kW power had been employed to weld commercial purity titanium tubes with 0.5 mm wall thickness and 50 mm diameter. For comparison purposes, semiautomatic TIG welding was realized. The chosen parameters speed and laser power for laser welding were 200 W–2 m/min and 250 W–3 m/min. The laser welded tubes presented 1 mm wide weld beads composed by partially twinned α-Ti grains. The TIG welded tubes showed 5 mm wide beads composed by acicular α-grains. These observed differences had been associated with the cooling rates, which are ten times higher in the laser case. Both laser and TIG welded tubes were cycled 44,000 times in a pneumatic bench at 350 °C without failures or cracks that could release the internal pressure. After the pressurization tests, the tubes were tested for tensile and fatigue resistance. The yield stresses, tensile strengths and total elongation did not change comparing base material, TIG welded and laser welded cases. The condition 200 W–2 m/min presented superior fatigue resistance values compared to other welding conditions, and could be considered similar to the tubes in the unwelded condition. The microstructural and mechanical results had shown that the current laser technology can replace, with advantages, the arc welding for the joining of the titanium tubes.