The objective underlined in this work is to apply Rotary Friction Welding (RFW) process to joint similar AA2024 and TiAl6V4 welds. The experiment is conducted by varying the input parameters (rotational speed, friction pressure and friction time) using Taguchi’s L9 orthogonal array method. MINITAB software was used to plot the response chart. The output parameter considered in this approach is the Ultimate Tensile Strength (UTS) of the weld joint, where the optimum RFW condition for maximizing the UTS were determined. Besides, the most influential process parameter has been determined using statistical analysis of variance (ANOVA). Finally, the general regression equations of the UTS for both materials are formulated and confirmed by means of the experimental tests values.

In this study, friction stir spot welding (FSSW) is applied to join the TiAl6V4 titanium alloy with 1.5 mm thickness and then the effect of rotational speed and tool dwell time on microstructure and mechanical properties is investigated. In this regard, the speed of the tool rotation was considered as 800, 1000, and 1200 rpm, as well as the tool dwell time was set at 7 and 12s. Microstructural evaluation was carried out using optical microscopy (OM) and scanning electron microscopy (SEM). In addition, tensile-shear and hardness studies were performed to analyze mechanical properties. The obtained results from microstructural evaluation show that the welded joints consist of two regions, namely the SZ and the HAZ-regions. Additionally, microstructure of the SZ-region was identified in the form of a/b layer within the initial b-phase. The results of tensile/shear tests and micro-hardness test indicated that the joint strength and hardness are enhanced with increasing the rotational speed and dwell time. The tensile/shear strength is increased from 2.7 to 15 KN with increasing the rotational speed at constant dwell time of 7s, and also is increased from 7.3 to 17.25 KN with increasing the rotational speed at constant dwell time of 12s. The maximum tensile/shear strength was achieved for the welded joint with the dwell time of 12s and rotational speed of 1250 rpm. The hardness of SZ, HAZ regions and base metal are measured around 380 to 420, 340 to 380, and 300 to 340, respectively.

In this study, the effect of coating processing time on microstructure of surface and corrosion resistance of coatings resulted by plasma electrolytic oxidation (PEO) was investigated on substrate of TiAl6V4 alloy. The coating processes in hydroxyapatite nano-powder electrolytic were carried out in same conditions of constant voltage of 600V and three different times of 125, 250 and 350 seconds. Studying the microstructure of coatings identified that the coating formed in 125 (s) had more compact and steady structure with fine surface cavities and less porosity. X-ray diffraction pattern of coating demonstrates that this coating is consists of oxide phases of titanium (rutile and anatase) and hydroxyapatite. Also, the study of corrosion resistance of coatings by Potentiodynamic polarization and electrochemical impedance spectroscopy in corrosive solution of chloride sodium 3. 5% showed that the coating formed in 125 s has the most noble corrosion resitance potential and the least ICorr and finally the highest resistance to corrosion.