Modeling of upset and torsional moment during inertia friction welding

Keßler, Manuel; Suenger, S.; Haubold, Martin; Zaeh, Michael F.

doi:10.1016/j.jmatprotec.2015.07.024

Cited by 14 publications

(9 citation statements)

References 10 publications

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“…Inertia friction welding (IFW) can also be used instead of RFW as the drive required is small for similar specimen dimensions. IFW is also a proven weld technique with a regression model to test the influence of parameters [13]. Welding becomes risky and unhealthy unless the right precautions and safety measures are followed.…”

Section: Fig 2 Friction Welding Process Parameters With Timementioning

confidence: 99%

Rotary Friction Welding and Dissimilar Metal Joining of Aluminium and Stainless Steel Alloys

Murugan¹,

Sathiya

Haq

2021

AWET

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Friction welding (FW) is cost-effective, efficient, occupational safer and also eco-friendly in the absence of pollution, smoke, fume, and IR radiation during welding than conventional welding technologies. In this paper, the joining of aluminium AA6063 and steel SS304 dissimilar metal is explained with different faying surfaces and their SEM images of weld interface (WI), joint quality, tensile and yield strength, and the axial shortening are evaluated and compared. The joint quality factor of the experiment faying surface modification ‘E3’ was the maximum and about >100% with 236 MPa strength. The axial shortening was also less than 27 mm. The joint with hemispherical faying surface showed ‘U’ shaped WI and the joint with taper faying surface showed ‘V’ shape WI. So, the cross-sectional area of WI can be increased and the strength also increased. FW yields very high strength, low-stress weld with no weld defects such as porosity, voids etc. Here, in most cases, the joint strength is equal to base metal strength and it can avoid fastening to join two metals. FW has a minimal and narrow heat-affected zone (HAZ) of few microns size that differentiates FW from other welding techniques. The grain size of HAZ is directly proportional to the heat input during welding. During fusion welding of dissimilar materials, a lot of intermetallic compounds are formed at the weld interface and that will lead to poor strength of the welding because they have different chemical and mechanical qualities; therefore FW is a good choice for joining dissimilar metal rods as the intermetallic compounds can be reduced by FW.

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Section: Fig 2 Friction Welding Process Parameters With Timementioning

confidence: 99%

Rotary Friction Welding and Dissimilar Metal Joining of Aluminium and Stainless Steel Alloys

Murugan¹,

Sathiya

Haq

2021

AWET

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“…By using the RFW machine described by Loehe et al [17] and Kessler et al [2], experiments were conducted to validate the model. The machine was initially built with a flywheel as an energy supply.…”

Section: Rfw Machinementioning

confidence: 99%

Simulation of rotary friction welding using a viscoelastic Maxwell model

Keßler

Hartl

Fuchs

et al. 2020

Science and Technology of Welding and Joining

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A 3-D finite element model of rotary friction welding was developed using a viscoelastic Maxwell model. The thermal softening of the material was accounted for in the viscous part of the material model as well as in an additional friction model. The thermal and mechanical material data were adapted from existing data of tempering steel AISI 4140. The final model was used to predict rotary friction welding of shafts using three different parameter settings. The simulation results showed that the melt temperature was never exceeded at the faying surfaces, which is seen as a main characteristic of friction welding. Subsequent validation also demonstrated that the shortening of the specimen as well as the resulting flash geometry could be predicted successfully.

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“…The application of RFW, in many industries such as aircraft structures and aero engine components, is required to join dissimilar metals which is inevitable now a days [3][4]. Similar to it, linear friction welding (LFW) and inertia friction welding (IFW) were also used to join the dissimilar metals which gain the more interest now a days [5][6]. In welding of aluminium-stainless steel dissimilar metals using inertia friction welding, the intermetallic compound layer generated at the interface of joining which was seen to be increases with the increment in the rotational speed [7].…”

Section: Introductionmentioning

confidence: 99%

Effect of friction-welding parameters on the tensile strength of AA6063 with dissimilar joints

Chapke

Kamble

2022

Frattura Ed Integrità Strutturale

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In this paper, the effect of welding parameters of rotary friction welding between AA6063 and AISI4130 and AA6063 and Copper are investigated. The major influencing parameters considered are upset pressure, friction time and friction pressure of friction welding are considered for this study. The Taguchi’s design of experiments was conducted for the influencing parameters and their levels. The tensile test experimentation was carried out and the results of the AA6063 and AISI4130 and AA6063 and Copper are compared. The ultimate tensile strength of AA6063-AISI4130 joint and AA6063-Copper joint was improved by increasing upset pressure up to 97MPa with FP of 71 MPa and FT of 4 sec. On the side of AA6063, intermetallic compounds have formed, as seen in SEM micrographs. Microcracks are forming on the side of AA6063 and propagates along the grain boundaries. The effect of the influencing parameters on the tensile strength of the dissimilar joints are studied using the Taguchi’s DOE and ANOVA. From the outcomes it is observed that the friction pressure influence more on the strength of the AA6063 dissimilar joints.

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Modeling of upset and torsional moment during inertia friction welding

Cited by 14 publications

References 10 publications

Rotary Friction Welding and Dissimilar Metal Joining of Aluminium and Stainless Steel Alloys

Rotary Friction Welding and Dissimilar Metal Joining of Aluminium and Stainless Steel Alloys

Simulation of rotary friction welding using a viscoelastic Maxwell model

Effect of friction-welding parameters on the tensile strength of AA6063 with dissimilar joints

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