“…27 To this effect, the experimental power-travel method has been used to calculate heat input to the interface and ignore the friction coefficient estimation problem. 28 Another alternative method is to assume that friction stress ( τ f ) is equal to the shear yield stress ( τ y ) at the interface. 29 In such a case employing the von Mises yield stress, it can be expressed as:…”
Section: Process Parametersmentioning
confidence: 99%
“…9 b ) as experiments showed. 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44,45 Another process parameter, the welding pressure at high enough values affects material expulsion rate from the interface. Bhamji et al 21 found that it is proportional to burn-off rate, and inversely proportional to the required friction time once a limit has been passed. 9 Relationship between average heat input and axial shortening for Ti64 a 43 and mild steel b 44 obtained by numerical modelling…”
Friction welding (FW) is a high quality, nominally solid-state joining process, which produces welds of high structural integrity. Rotary friction welding (RFW) is the most commonly used form of FW, while linear friction welding (LFW) is a relatively new method being used mainly for the production of integrally bladed disc (blisk) assemblies in the aircraft engine industry. Numerous similar and dissimilar joints of structural metallic materials have been welded with RFW and LFW. In this review, the current state of understanding and development of RFW and LFW is presented. Particular emphasis is placed on the process parameters, joint microstructure, residual stresses, mechanical properties and their relationships. Finally, opportunities for further research and development of the RFW and LFW processes are identified.
“…27 To this effect, the experimental power-travel method has been used to calculate heat input to the interface and ignore the friction coefficient estimation problem. 28 Another alternative method is to assume that friction stress ( τ f ) is equal to the shear yield stress ( τ y ) at the interface. 29 In such a case employing the von Mises yield stress, it can be expressed as:…”
Section: Process Parametersmentioning
confidence: 99%
“…9 b ) as experiments showed. 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44,45 Another process parameter, the welding pressure at high enough values affects material expulsion rate from the interface. Bhamji et al 21 found that it is proportional to burn-off rate, and inversely proportional to the required friction time once a limit has been passed. 9 Relationship between average heat input and axial shortening for Ti64 a 43 and mild steel b 44 obtained by numerical modelling…”
Friction welding (FW) is a high quality, nominally solid-state joining process, which produces welds of high structural integrity. Rotary friction welding (RFW) is the most commonly used form of FW, while linear friction welding (LFW) is a relatively new method being used mainly for the production of integrally bladed disc (blisk) assemblies in the aircraft engine industry. Numerous similar and dissimilar joints of structural metallic materials have been welded with RFW and LFW. In this review, the current state of understanding and development of RFW and LFW is presented. Particular emphasis is placed on the process parameters, joint microstructure, residual stresses, mechanical properties and their relationships. Finally, opportunities for further research and development of the RFW and LFW processes are identified.
“…In general, mathematical modeling [3,4] of any process can provide means for the apprehension, the prediction of the attributes of the process, and its performances. The characteristics and process parameters of CDFW can be analyzed by math-ematical modeling; thus, saving time and money.…”
Continuous drive friction welding process is widely used in various industrial applications to assemble shafts, tubes, and many other components. This paper's motivation was developing a CDFW model using the Finite Element Method (FEM). The coupling of the process's thermal and mechanical behaviors was considered during the simulation by COMSOL Multiphysics®. The construction of phase transition curves for Al6061 allowed determining several temperature-dependent thermophysical properties of the material. These properties are then injected in a second simulation to study the temperature evolution during welding. Subsequently, these results are compared and analyzed with the experimental outcomes. Excellent comparability between the model and experimental results was achieved. A unique phenomenon in the welding temperature profile was observed and explained through the model and experimental results interpretation.
“…The movement of the welded elements induces heat and plastic strain, which leads to mixing plasticized metal and the establishment of a metallic bond. The heat input depends on the relative velocity of the workpieces, the duration of the process, and the compressive axial force [21]. It possible to control the welding conditions, and therefore the microstructure and mechanical properties of the joined material.…”
Copper rods with ultrafine-grained microstructure, obtained by multi-turn ECAP processing, were subjected to Direct Drive Rotary Friction Welding using various processing parameters, such as rotational speed and pressure, which resulted in different energy and heat input. Even though friction welding is a high energy process, by a proper selection of processing parameters it was possible to maintain grain size at around 0.7 µm in the weld zone and preserve the UFG microstructure. These microstructural features translated into mechanical properties: the YS for those specimens was around 330 MPa. Processing parameters that resulted in a larger heat input caused an increase in grain size to around 2 µm; this, however, increased ductility and led to a uniform elongation exceeding 5%. Corrosion resistance in the stir zone increased, as was evident in the higher open circuit potential and higher corrosion potential in comparison with base material; the observed differences were about 50 mV. These changes can be explained by the higher fraction of HAGBs in the SZ.
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