Sequential Transient Numerical Simulation of Inertia Friction Welding Process

The joining of ceramic and metals can be done by different techniques such as ultrasonic joining, brazing, transient liquid phase diffusion bonding, and friction welding. Friction Welding is a solid state joining process that generates heat through mechanical friction between a moving workpiece and a stationary component. In this article, numerical simulation on thermal analysis of friction welded ceramic/metal joint has been carried out by using Finite Element Analysis (FEA) software. The finite element analysis helps in better understanding of the friction welding process of joining ceramics with metals and it is important to calculate temperature and stress fields during the welding process. Based on the obtained temperature distribution the graphs were plotted between the lengths of the joint corresponding to the temperatures. To increase the wettability, aluminium sheet was used as an interlayer. Hence, numerical simulation of friction welding process is done by varying the interlayer sheet thickness. Transient thermal analysis had been carried out for each cases and temperature distribution was studied. From the simulation studies, it is found that the increase in interlayer thickness reduces the heat affected zone and eventually improves the joint efficiency of alumina/aluminum alloy joints.

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NUMERICAL SIMULATION OF TEMPERATURE FIELD FOR INERTIA FRICTION WELDING OF SUPERALLOY

Journal of Mechanical Engineering ◽

10.3901/jme.2002.supp.200 ◽

2002 ◽

Vol 38 (supp) ◽

pp. 200

Author(s):

Liwen Zhang

Keyword(s):

Numerical Simulation ◽

Temperature Field ◽

Friction Welding ◽

Inertia Friction Welding

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226 Thermo-mechanical simulation of inertia friction welding process

The Proceedings of The Computational Mechanics Conference ◽

10.1299/jsmecmd.2015.28._226-1_ ◽

2015 ◽

Vol 2015.28 (0) ◽

pp. _226-1_-_226-2_

Author(s):

Yuta KITAMURA ◽

Mitsuyoshi TSUNORI ◽

Shinji MAEKAWA

Keyword(s):

Friction Welding ◽

Welding Process ◽

Inertia Friction Welding ◽

Mechanical Simulation

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Sequential Transient Numerical Simulation of Inertia Friction Welding Process

Volume 10: Heat Transfer, Fluid Flows, and Thermal Systems, Parts A, B, and C ◽

10.1115/imece2008-67570 ◽

2008 ◽

Author(s):

Medhat Awad El-Hadek ◽

Mohammad S. Davoud

Keyword(s):

Temperature Distribution ◽

Residual Stresses ◽

Friction Welding ◽

Welding Process ◽

Transient Temperature ◽

Inertia Friction Welding ◽

Residual Stress Field ◽

Element Analysis ◽

Full Field ◽

Welding Processes

Inertia friction welding processes often generate substantial residual stresses due to the heterogeneous temperature distribution during the welding process. The residual stresses which are the results of incompatible elastic and plastic deformations in weldment will alter the performance of welded structures. In this study, three-dimensional (3D) finite element analysis has been performed to analyze the coupled thermo-mechanical problem of inertia friction welding of a hollow cylinder. The analyses include the effect of conduction and convection heat transfer in conjunction with the angular velocity and the thrust pressure. The results include joint deformation and a full-field view of the residual stress field and the transient temperature distribution field in the weldment. The shape of deformation matches the experimental results reported in the literature. The residual stresses in the heat-affected zone have a high magnitude but comparatively are smaller than the yield strength of the material.

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3D Numerical Simulation of Linear Friction Welding of 45# Carbon Steel

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.476-478.701 ◽

2012 ◽

Vol 476-478 ◽

pp. 701-704

Author(s):

Ze Min Liu ◽

Zheng Hua Guo ◽

Gang Yao Zhao ◽

Shu Zhang ◽

Ji Luan Pan

Keyword(s):

Numerical Simulation ◽

Carbon Steel ◽

Friction Welding ◽

Flow Behavior ◽

Metal Flow ◽

Welding Process ◽

Contact Boundary ◽

Linear Friction Welding ◽

Welding Interface ◽

Linear Friction

A 3D finite-elements model of 45# carbon steel of linear friction welding is built with the dynamic explicit code ABAQUS/explicit based on the solution of several key techniques, such as contact boundary condition treating, material properties definition, meshing technology, etc. Then the reliability of the model is validated by comparison with experiments in the literature. Furthermore, numerical simulation and analysis of the linear friction welding process of 45# steel have been carried out by using the model. The temperature field of workpiece, the temperature change of center point of welding interface and the metal flow behavior of welding interface are showed in results.

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