Finite element modelling of the inertia friction welding process between dissimilar materials

2002 ◽  
Vol 125-126 ◽  
pp. 387-391 ◽  
Author(s):  
L. D’Alvise ◽  
E. Massoni ◽  
S.J. Walløe
Keyword(s):  
Finite Element ◽  
Friction Welding ◽  
Finite Element Modelling ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Inertia Friction Welding ◽  
Element Modelling

scholarly journals FINITE ELEMENT BASED THERMAL MODELING OF FRICTION WELDING OF DISSIMILAR MATERIALS

2013 ◽  
Vol 22 ◽  
pp. 196-202 ◽  
Author(s):  
N. RAJESH JESUDOSS HYNES ◽  
P. NAGARAJ ◽  
R. MEBY SELVARAJ
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Friction Welding ◽  
Thermal Modeling ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Element Approach ◽  
Stress Formation ◽  
Role Based ◽  
Solid State Joining

Friction welding is a solid state joining process of joining either similar or dissimilar materials. Joining of ceramic/metal joints by friction welding has opened up new possibilities in many engineering applications. In the present work, thermal modeling of friction welding process has been carried out. Using Finite Element Approach (FEA), analytical solutions were arrived for different ceramic/metal combinations. The temperature distributions of cylindrical surfaces of the alumina and the metals are found by means of 1D heat transfer assumption considering the effect of convection. In the thermal analysis, interfacial temperature and thermal conductivity of the material play a significant role. Based on the obtained temperature distribution the graphs are plotted between the length of the joint and the temperatures. Thus the knowledge of the temperature joint distribution could be helpful in predicting the thermal cycle of the process, microstructure evolution and residual stress formation. Thus the obtained graph helps to study and predict the temperature distribution of both the materials.

Finite Element Modelling of Temperature Distribution in Friction Stir Welding Process and Its Influence on Distortion of Copper Canisters

2004 ◽  
Vol 824 ◽  
Author(s):  
Therese Källgren ◽  
Lai-Zhe Jin ◽  
Rolf Sandström
Keyword(s):  
Finite Element ◽  
Friction Stir Welding ◽  
Temperature Distribution ◽  
Welding Speed ◽  
Material Flow ◽  
Finite Element Modelling ◽  
Welding Process ◽  
Element Modelling ◽  
Friction Stir ◽  
Friction Stir Welding Process

AbstractIn an effort to enhance safety for long time disposal of waste nuclear fuel, friction stir welding has been developed as one alternative to seal copper canisters. To avoid the formation of voids and cracks during the welding process, an understanding of the heat and material flow andthereby the evolution of the microstructure, is of great importance. Finite element modelling has been used to simulate the heat and material flow as well as thermal expansion during the friction stir welding process. A model involving heat transfer, material flow, and continuum mechanics has been developed. The steady state solutions have been compared with experimental temperature observations as well as analytical solutions, showing good agreement. Temperature distribution is affected by the welding speed. For a given reference pointperpendicular to the welding direction, a lower welding speed corresponds to a higher peak temperature. The plunging position of welding tool influences the temperature distribution and therefore the displacement distribution of the weldment.

Finite Element Simulation of Microstructural Evolution during Inertia Friction Welding Process of Superalloy GH4169

2011 ◽  
Vol 675-677 ◽  
pp. 975-978
Author(s):  
Wei Xu ◽  
Li Wen Zhang ◽  
Chong Xiang Yue
Keyword(s):  
Grain Size ◽  
Finite Element ◽  
Microstructural Evolution ◽  
Friction Welding ◽  
Weld Line ◽  
Welding Process ◽  
Equivalent Strain ◽  
Fe Model ◽  
Inertia Friction Welding ◽  
Element Simulation

During the inertia friction welding (IFW) process of superalloy GH4169, the main mechanism for microstructural evolution is dynamic recrystallization (DRX). In order to investigate the microstructural evolution during the process, a finite element (FE) model coupled with the DRX model of the alloy was developed on the platform of MSC.Marc. Equivalent strain was introduced into the DRX model to improve the computational precision. As a result, the IFW process with microstructural evolution was simulated. Simulated results reveal that DRX region is very small. Fully recrystallized region and fine grains appear near the weld line. Dynamically recrystallized fraction (DRXF) decreases and grain size increases with the increase of the distance from the weld line. Predicted results of microstructural distribution agree well with experimental ones.

The Evaluation of Coefficient of Friction for Representative and Predictive Finite Element Modelling of the Inertia Friction Welding

2009 ◽  
Author(s):  
M. B. Mohammed ◽  
C. J. Bennett ◽  
T. H. Hyde ◽  
E. J. Williams
Keyword(s):  
Finite Element ◽  
Coefficient Of Friction ◽  
Friction Welding ◽  
Mechanical Energy ◽  
Rotational Velocity ◽  
Welding Process ◽  
High Strength ◽  
Weld Interface ◽  
Inertia Friction Welding ◽  
Finite Element Software

Inertia friction welding is the process in which stored kinetic energy in a flywheel is converted to heat by relative sliding movement between surfaces of axi-symmetric components to achieve a weld in the solid-state. The work in this paper relates to the production of dual-alloy shafts for aeroengines. Frictional characteristics determine the conditions at the weld interface and these are controlled by rotational velocity and applied axial pressure. So-called representative and predictive methods have been developed to evaluate friction conditions during the process and these are discussed in this paper. Weld data for the dissimilar weld between a high strength steel and a nickel-based super-alloy were provided by Rolls-Royce and MTU Aero Engines. The finite element software package DEFORM-2D is used to develop coupled thermo-mechanical axi-symmetric models. In previous work, methods employed to evaluate the efficiency of mechanical energy utilised during a weld, a parameter of great importance for numerical analysis, are not clear. Previous predictive approaches have employed test/weld data in one way or another to obtain the interface friction coefficient. This paper proposes a formula that incorporates the value of the mechanical energy efficiency of the welding machine into the calculation of coefficient of friction for representative modelling. It also introduces a predictive approach based on sub-layer flow theory to predict frictional behaviour during the welding process that is independent of test/weld data.

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