Application of Optimal Control Algorithm to Inertia Friction Welding Process

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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Sequential Transient Numerical Simulation of Inertia Friction Welding Process

International Journal for Computational Methods in Engineering Science and Mechanics ◽

10.1080/15502280902795086 ◽

2009 ◽

Vol 10 (3) ◽

pp. 224-230 ◽

Cited By ~ 2

Author(s):

Medhat Awad El-Hadek

Keyword(s):

Numerical Simulation ◽

Friction Welding ◽

Welding Process ◽

Inertia Friction Welding ◽

Transient Numerical Simulation

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FE Modeling of the Inertia Friction Welding with a Modified Friction Law

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.740.55 ◽

2015 ◽

Vol 740 ◽

pp. 55-58

Author(s):

Quan Zhong Zhang ◽

Li Fen Hu ◽

Wu Bin Li ◽

Jiu Chun Gu

Keyword(s):

Friction Welding ◽

Welding Process ◽

Friction Model ◽

Friction Torque ◽

Work Piece ◽

Fe Model ◽

Inertia Friction Welding ◽

Friction Law ◽

The Subject ◽

Coulomb Friction Model

The subject of this paper was the presentation of a holistic, fully-temperature-coupled FE model of inertia friction welding based on the modified friction law, which divided the friction welding process into beginning friction stage and steady equilibrium friction stage. At each of the stage Coulomb friction model and shear friction model were adopted respectively. The present FE model predicted the temperature of the welding joint as well as variation of friction torque and relative rotating velocity of the work-piece during the welding process. The evolution of friction torque and rotating velocity were compared with the experimental measurement. They showed a good agreement between them.

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The Coupled Thermal Mechanical Modeling of the Inertia Friction Welding Process for Inconel718

Materials Science Forum ◽

10.4028/www.scientific.net/msf.704-705.710 ◽

2011 ◽

Vol 704-705 ◽

pp. 710-716 ◽

Cited By ~ 1

Author(s):

Wen De Bu ◽

Jin He Liu

Keyword(s):

Friction Welding ◽

Welding Process ◽

Mechanical Analysis ◽

Friction Torque ◽

Interface Temperature ◽

Deformation Pattern ◽

Fe Model ◽

Inertia Friction Welding ◽

Conservation Of Energy ◽

True Shape

In this paper, numerical modeling of inertia friction welding (IFW) for Inconel718 was performed using ABAQUS/Explicit with a 3D finite-element (FE) model and the coupled thermo-mechanical analysis. A new thermal input model has been deduced according to the characteristics of IFW and law of conservation of energy. The evolution of temperature field as well as the deformation pattern of the inertia welded joint has been predicted. It is shown that the interface temperature firstly increases rapidly to about 1100 °C within 3 s and then increases slowly. The energy input rate at the interface during the IFW process is closely related to the rotational speed and friction torque of flywheels. The temperature distribution at the interface is very inhomogeneous especially at the initial stage and finally tends to become uniform with the increase of time. Consequently, the flash start to appear as the interface temperature becomes homogeneous relatively and the plastic flow of metal at the interface happens. The verifying trial was carried out and the predicted temperature was compared with the experimental data measured by means of thermocouples. The shape of flash in simulation result was contrasted with the true shape of specimen under the same welding conditions. It is noted that the simulation results agrees well with the experimental results.

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Numerical Simulation of the Inertia Friction Welding Process of Dissimilar Materials

Metallurgical and Materials Transactions B ◽

10.1007/s11663-014-0148-2 ◽

2014 ◽

Vol 45 (6) ◽

pp. 2346-2356 ◽

Cited By ~ 3

Author(s):

Medhat A. El-Hadek

Keyword(s):

Numerical Simulation ◽

Friction Welding ◽

Welding Process ◽

Dissimilar Materials ◽

Inertia Friction Welding

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

Materials Science Forum ◽

10.4028/www.scientific.net/msf.675-677.975 ◽

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.

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