Friction Welding of Thixocast A356 Aluminium Alloy

2012 ◽  
Vol 192-193 ◽  
pp. 305-310 ◽  
Author(s):  
Shailesh K. Singh ◽  
Kamanio Chattopadhyay ◽  
Pradip Dutta
Keyword(s):  
Finite Element Method ◽  
Friction Welding ◽  
Flow Behavior ◽  
A356 Alloy ◽  
Welding Process ◽  
Fem Analysis ◽  
Compression Tests ◽  
Cast Material ◽  
A356 Aluminium Alloy ◽  
Conventionally Cast

In this paper, a numerical model for friction welding of thixo-cast materials is developed, which includes a coupling of thermal effect and plastic deformation using a finite element method (FEM). As the constitutive equations for flow behavior of materials for a thixo-cast material are expected to be different from those of conventionally cast material of the same alloy, the necessary material data are experimentally determined from isothermal hot compression tests of the A356 thixocast alloy. The Johnson-Cook model has been employed to represent the flow behavior of the thixocast A356 alloy. The purpose of this FEM analysis is to provide better understanding of the friction welding process of thixo-cast material, and to obtain optimized process parameters before an actual welding is carried out.

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

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.

Thermomechanical Modelling of Direct-Drive Friction Welding Applying a Thermal Pseudo Mechanical Model for the Generation of Heat

2018 ◽  
Vol 767 ◽  
pp. 343-350
Author(s):  
Mads Rostgaard Sonne ◽  
Jesper Henri Hattel
Keyword(s):  
Friction Welding ◽  
Mechanical Model ◽  
Welding Process ◽  
Outer Diameter ◽  
Direct Drive ◽  
Compression Tests ◽  
Temperature Dependent ◽  
Thermomechanical Model ◽  
Friction Stir ◽  
Good Agreement

In the present work a 2D axisymmetric thermomechanical model of the direct-drive friction welding process is developed, taking the temperature dependent shear yield stress into account in the description of the heat generation, utilizing a recent thermal pseudo mechanical model originally developed for the friction stir welding (FSW) process. The model is implemented in ABAQUS/Explicit via a subroutine. The application in this case is joining of austenitic stainless steel rods with an outer diameter of 112 mm, used for manufacturing of exhaust gas valves for large two stroke marine engines. The material properties in terms of the temperature dependent flow stress curves used both in the thermal and the mechanical constitutive description are extracted from compression tests performed between 20 °C and 1200°C on a Gleeble 1500 thermomechanical simulator. Comparison between measured and simulated transient temperatures shows relatively good agreement and furthermore, the simulated deformations in terms of upsetting length and flash formation are also in good agreement with the observations from the experiment.

scholarly journals Microstructural evolution in linear friction welding process for Ti–6Al–4V alloy and its FEM analysis

2018 ◽  
Vol 68 (10) ◽  
pp. 544-551
Author(s):  
Hiroaki Matsumoto ◽  
Gen Yamane ◽  
Tomomichi Ozaki ◽  
Koji Nezaki ◽  
Takahiko Shinohara
Keyword(s):  
Microstructural Evolution ◽  
Friction Welding ◽  
Welding Process ◽  
Fem Analysis ◽  
Linear Friction Welding ◽  
Linear Friction

scholarly journals Analysis of the friction (spin) welding – preliminary study

2019 ◽  
Vol 254 ◽  
pp. 02036 ◽  
Author(s):  
Michał Pietrzak ◽  
Krzysztof Wałęsa ◽  
Jan Górecki ◽  
Maciej Berdychowski
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Additional Data ◽  
Theoretical Calculations ◽  
Welding Process ◽  
Fem Analysis ◽  
Welding Parameters ◽  
The Finite Element Method ◽  
Friction Heat ◽  
Preliminary Study

This article applies to the glue-free bonding of the components made of thermoplastics, specific techniques that use friction heat to plasticize and then join two surfaces. The featured technique is a friction (spin) welding process. Welding parameters were investigated and presented. Spin welding is known to consist of four phases. Analytical calculations were made for the first step. They are focused on the changeability of welding parameters depending on weld velocity. In the next part of this article, calculations including the finite element method were performed. This provided additional data and visualization of the process, which were not available in analytical calculations. Final results of both methods were compared. This made it possible to verify the correctness of theoretical calculations and exactness of FEM analysis.

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 Application of the Strain Compensation Model and Processing Maps for Description of Hot Deformation Behavior of Metastable β Titanium Alloy

Materials ◽  
2021 ◽  
Vol 14 (8) ◽  
pp. 2021
Author(s):  
Oleksandr Lypchanskyi ◽  
Tomasz Śleboda ◽  
Aneta Łukaszek-Sołek ◽  
Krystian Zyguła ◽  
Marek Wojtaszek
Keyword(s):  
Titanium Alloy ◽  
Strain Rate ◽  
Flow Behavior ◽  
Microstructural Analysis ◽  
Calculated Data ◽  
Processing Temperature ◽  
Processing Maps ◽  
Compression Tests ◽  
Strain And Strain Rate ◽  
Average Absolute Relative Error

The flow behavior of metastable β titanium alloy was investigated basing on isothermal hot compression tests performed on Gleeble 3800 thermomechanical simulator at near and above β transus temperatures. The flow stress curves were obtained for deformation temperature range of 800–1100 °C and strain rate range of 0.01–100 s−1. The strain compensated constitutive model was developed using the Arrhenius-type equation. The high correlation coefficient (R) as well as low average absolute relative error (AARE) between the experimental and the calculated data confirmed a high accuracy of the developed model. The dynamic material modeling in combination with the Prasad stability criterion made it possible to generate processing maps for the investigated processing temperature, strain and strain rate ranges. The high material flow stability under investigated deformation conditions was revealed. The microstructural analysis provided additional information regarding the flow behavior and predominant deformation mechanism. It was found that dynamic recovery (DRV) was the main mechanism operating during the deformation of the investigated β titanium alloy.

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.

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