Frictional heat generated in the early stages of an orbital friction welding process

Wear ◽  
1987 ◽  
Vol 114 (3) ◽  
pp. 355-365 ◽  
Author(s):  
R.E. Craine ◽  
A. Francis
Keyword(s):  
Friction Welding ◽  
Welding Process ◽  
Frictional Heat ◽  
Early Stages

Tensile Strength Characteristic of Al6061-T6 and Al7003-T6 Aluminum by the Change in the Friction Welding Process Variable

2014 ◽  
Vol 532 ◽  
pp. 534-539
Author(s):  
Hyun Sik Kim ◽  
Dong Pyo Hong ◽  
Sung Mo Yang ◽  
Hee Yong Kang
Keyword(s):  
Tensile Strength ◽  
Friction Welding ◽  
Welding Process ◽  
Hardness Test ◽  
Process Variable ◽  
Frictional Heat ◽  
Process Time ◽  
Pure Material ◽  
Aluminum Specimen ◽  
Welding Part

Recently, the various welding methods are used in the coupling method of product for the streamlining of complex products, simplification of manufacturing process, and decreasing process time a variety of industries. In this welding area, the friction welding technique has many advantages such as the mass production of rapid and highly reliable product and eases of automation, reduction of process time etc. so the domestic/external many studies are conducting. In this study, the Spindle speed, Up-set pressure as the necessary process variables for friction welding were change variously by using the round bar specimen of Al6061-T6 and Al7003-T6 Aluminum material, so the friction welding performance of the specimen by each change was compared and analyzed. In order to comprehend the friction welding performance, the frictional pressure was fixed with 20MPa, the spindle velocity was changed with 1,000, 1,500, 2,200rpm, and the Up-set pressure was changed with 35, 50, 65MPa for producing, so the performance by the specimen was compared and analyzed through the final tensile strength test. In addition, the effects of the friction welding on the specimen were examined through the analysis on the welding part hardness of the each friction welded aluminum specimen. In the result of the study, it showed the highest welding characteristic with the tensile strength 250.5MPa by applying 1,000rpm spindle velocity, 50MPa Up-set pressure compared to the lowest tensile strength 171.6MPa. In addition, as the result of hardness test, the hardness of specimen after conducting the friction welding of specimen decreased compared to the hardness of the pure material in the welding boundary, so it is judged that the measure to minimize the effects of the frictional heat by minimizing the friction welding time is needed.

Temperature Modeling for Friction Welding Process between Ceramic and Metal

2010 ◽  
Vol 64 ◽  
pp. 115-124
Author(s):  
Hazman Seli ◽  
Ahmad Izani Md. Ismail ◽  
Endri Rachman ◽  
Zainal Arifin Ahmad
Keyword(s):  
Friction Welding ◽  
Welding Process ◽  
Thermal Response ◽  
Frictional Heat ◽  
One Dimensional ◽  
Heating And Cooling ◽  
Temperature Modeling ◽  
Model Of Friction ◽  
Transient Thermal ◽  
Transient Thermal Response

Numerical model of friction welding between ceramic and metal rods are established to predict temperature rises during the initial phase of the process. In this study alumina(ceramic) and mild steel(metal) rods are used and joined with aluminium sacrificial interlayer. The workpieces are welded together by holding alumina still, while rotating the steel attached with aluminium piece under influence of an axial load which creates frictional heat in the interfaces. The transient thermal response in welding is hard to model analytically. Generally, heat is dissipated over time scales of less than two seconds. For the thermal model, an explicit one dimensional (1-D) finite difference (FD) method is utilized to approximate the heating and cooling temperature distribution of the joined dissimilar rods. The preliminary predictions are compared to actual thermocouple data from welds conducted under identical conditions and are shown to be in fair agreement. Even though the FD method proposed in this study cannot replace a more accurate numerical analysis, it does provide guidance in weld parameter development and allows better understanding of the friction welding process.

Dissimilar Study on Friction Welding of AA 2025 Tube Plate to Copper Tube Using an External Tool

2016 ◽  
Vol 852 ◽  
pp. 362-368
Author(s):  
G. Gokul ◽  
S. Senthil Kumaran
Keyword(s):  
Plastic Deformation ◽  
Solid State ◽  
Friction Welding ◽  
Rotation Speed ◽  
Welding Process ◽  
Copper Tube ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Work Piece ◽  
Tube Plate

In this project the feasibility of friction welding in tube to tube plate using an external tool (FWTPET) of commercial Copper and Aluminum 2025 tube plate is investigated using an clearance fit method and the process parameters have been prioritized using Taguchi’s L27 orthogonal array. Than experiment is conducted and take results are compressive strength and hardness testing, Radiography test, Scanning Electron Microscopy and Energy Dispersive Spectroscopy testing. Aluminum 2025 are widely used in aerospace, automotive, marine, defense, construction etc. Friction welding is preferred for joining these materials as it is a solid state forge welding process and problems related with welding of aluminum tube plate and copper tube can be subdued through this process. This welding process is a solid state welding procedure that uses a non-consumable rotating tool that is permitted to rub against the work piece hence generating frictional heat. When the weld constraints such as tool rotation speed, welding time, axial load are optimum the friction between the work piece and the tool generates enough heat to create a plastic deformation layer at the weld interface. The process doesn’t involve any melting process and whole process occurs in solid state through plastic deformation and mass flow among the work pieces. The experimental investigation of FWTPET is done by varying the friction welding parameters such as work piece rotation speed, depth and projection. The work piece is rotated at the speeds 285 rpm, 480 rpm and 750rpm, projection 0 mm,1 mm,2 mm and depth are0.5 mm,1 mm,1.5 mm.The experiment is done in a general purpose vertical milling machine. To hold the work piece a fixture is designed. A tool is also designed. This work confirms that a high quality tube to tube plate joint can be achieved using FWTPET process.

Analysis of the Influence of Continuous-Drive Friction Welding on the Microstructure and Mechanical Properties of the UNS C64200 Bronze-Aluminum-Silicon Alloy

2021 ◽  
Vol 412 ◽  
pp. 185-195
Author(s):  
P.S.P. Monteiro ◽  
Givanildo Alves dos Santos ◽  
Francisco Yastami Nakamoto ◽  
Mauricio S. Nascimento ◽  
Rogerio Teram ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Friction Welding ◽  
Base Material ◽  
Welding Process ◽  
Hardness Test ◽  
Temperature Characteristic ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Aluminum Silicon Alloy ◽  
Aluminum Silicon

Friction welding (FRW) is an important commercial solid-state welding process in which coalescence is achieved by frictional heat combined with pressure. The objective of this work is to analyze the microstructure and the mechanical behavior of the copper alloy UNS C64200 – bronze-aluminum-silicon, as well as to raise the ideal welding parameters so that there is adequate weldability after process of continuous-drive friction welding. Regarding the analysis of the microstructure, scanning electron microscopy was used to characterize phases. The mechanical properties were evaluated by means of a hardness test of the center of the welded joint, traversing the entire extent of the thermally affected zone. Results show that the UNS C64200 alloy, when subjected to conventional friction welding, behaves satisfactorily in terms of weldability, without the appearance of cracks or defects arising from the temperature characteristic of this process, as well as good hardness with values above the minimum established in norm and higher than the base material.

Friction welding of high Cr white cast iron to AISI 1030 steel with Ni interlayer

2021 ◽  
Vol 63 (11) ◽  
pp. 1012-1017
Author(s):  
Tanju Teker ◽  
Eyyüp Murat Karakurt
Keyword(s):  
Cast Iron ◽  
Friction Welding ◽  
Energy Dispersive Spectrometry ◽  
White Cast Iron ◽  
Welding Process ◽  
Vital Role ◽  
Frictional Heat ◽  
X Ray Diffraction ◽  
X Ray ◽  
Ni Interlayer

Abstract In this study, the effect of friction time on microstructure and weldability of AISI 1030 steel with nickel interlayer and high chromium white cast iron welded by the friction welding method were investigated experimentally. The weld joints were produced with 2000 rpm rotational speed, under 80 MPa friction pressure, 150 MPa forging pressure, for 8 s forging time and 8, 10 and 12 s friction times. After the friction welding process, the microstructures of the weld interfaces were analyzed by optical microscopy, scanning electron microscopy, energy dispersive spectrometry, elemental mapping and X-ray diffraction analysis. The results were lateron compared theoretically and experimentally. The increasing friction time led to high frictional heat input. The results indicated that friction time plays a vital role on the microstructure and weldability.

Efficiency of the Inertia Friction Welding Process and Its Dependence on Process Parameters

2017 ◽  
Vol 48 (7) ◽  
pp. 3328-3342 ◽  
Author(s):  
O. N. Senkov ◽  
D. W. Mahaffey ◽  
D. J. Tung ◽  
W. Zhang ◽  
S. L. Semiatin
Keyword(s):  
Process Parameters ◽  
Friction Welding ◽  
Welding Process ◽  
Inertia Friction Welding

scholarly journals Microstructure and Mechanical Properties of Dissimilar Friction Welding Ti-6Al-4V Alloy to Nitinol

Metals ◽  
2021 ◽  
Vol 11 (1) ◽  
pp. 109
Author(s):  
Ateekh Ur Rehman ◽  
Nagumothu Kishore Babu ◽  
Mahesh Kumar Talari ◽  
Yusuf Siraj Usmani ◽  
Hisham Al-Khalefah
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Flow Stress ◽  
Intermetallic Compound ◽  
Ultimate Tensile Strength ◽  
Friction Welding ◽  
Welding Process ◽  
Weld Interface ◽  
Dissimilar Joints ◽  
Dissimilar Alloys

In the present study, a friction welding process was adopted to join dissimilar alloys of Ti-Al-4V to Nitinol. The effect of friction welding on the evolution of welded macro and microstructures and their hardnesses and tensile properties were studied and discussed in detail. The macrostructure of Ti-6Al-4V and Nitinol dissimilar joints revealed flash formation on the Ti-6Al-4V side due to a reduction in flow stress at high temperatures during friction welding. The optical microstructures revealed fine grains near the Ti-6Al-4V interface due to dynamic recrystallization and strain hardening effects. In contrast, the area nearer to the nitinol interface did not show any grain refinement. This study reveals that the formation of an intermetallic compound (Ti2Ni) at the weld interface resulted in poor ultimate tensile strength (UTS) and elongation values. All tensile specimens failed at the weld interface due to the formation of intermetallic compounds.

scholarly journals Structure Analysis and Design of Automobile plastic clutch pump body based on friction welding

2020 ◽  
Vol 316 ◽  
pp. 02001
Author(s):  
Jing Sheng ◽  
Aamir Sohail ◽  
Mengguang Wang ◽  
Zhimin Wang
Keyword(s):  
High Temperature ◽  
Structural Design ◽  
Friction Welding ◽  
Room Temperature ◽  
Welding Process ◽  
Structure Type ◽  
Mechanical Analysis ◽  
Analysis And Design ◽  
Technical Requirements ◽  
Design Requirements

In order to realize the need for lightweight automobiles through replacing steel with plastics, the research and development of the plastic clutch pump body based on the friction welding was carried out. For the clutch pump body connected by friction welding process between the upper pump body and the lower pump body, the technical requirements of pressure 14 MPa and durability (high temperature 7.0 × 104 times, room temperature 7.0 × 105) are required. The structure type of the upper and lower pump bodies of the end face welding type was proposed. Through the static analysis of the pump body and weld and the mechanical analysis under the working condition, the structure of the clutch pump body (upper and lower pump body) was determined. According to the established welding process, the pressure of the clutch pump body is more than 15 MPa, and the number of high-temperature durable circulation and the number of room temperature durable circulation also reached 7.2×104 and 7.3×105 times respectively. The results show that the structural design of a clutch pump body meets the design requirements.

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