Numerical simulation based upon friction coefficient model on thermo-mechanical coupling in rotary friction welding corresponding with corona-bond evolution

Jin, Feng; Li, Jinglong; Du, Yajie; Nan, Xujing; Shi, Junmiao; Xiong, Jiangtao; Fu-sheng, Zhang

doi:10.1016/j.jmapro.2019.08.001

Cited by 33 publications

(18 citation statements)

References 13 publications

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“…The same also complies with the hypothesis that no heat generation due to frictional work would occur when the material is adequately softened or melted [20]. Such a friction law has widely been used for modeling of several variants of friction welding processes including rotary friction welding (RFW) [15,16,21], friction stir welding (FSW) [20] and friction hydropillar processing (FHPP) [18]. The values of η h and μ were considered as 0.5 and 0.3, respectively.…”

Section: Theoretical Formulationmentioning

confidence: 80%

“…where h b = 10.0 W m −2 K −1 . The peak temperature during solid state joining remains below the solidus temperature of the respective workpiece material [15][16][17][18][19][20][21][22][23][24]. Similar boundary conditions are used in numerical heat transfer modeling of FSW and stationary shoulder friction stir welding (SSFSW) processes [23,24].…”

Section: Theoretical Formulationmentioning

confidence: 99%

“…The process modeling has been the primary tool for a quantitative understanding of several solid-state joining processes involving complex thermo-mechanical phenomena. For example, Jin et al [15] and Schmicker et al [16] utilized a finite element method based model to explain the joining mechanism in RFW. D'Alvise et al [17] computed the flash foramtion in inertial friction welding using a finite element method based process simulation model.…”

Section: Introductionmentioning

confidence: 99%

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An investigation on girth friction welding of duplex stainless steel pipes

Kanan

Vicharapu

Pissanti

et al. 2020

Journal of Manufacturing Processes

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Girth friction welding is a novel technique to join co-axial linepipes with an external ring (girth) in solid state and without melting of materials. The ring or the girth is rotated between two pipes under an axial force resulting in frictional heat generation and plastic deformation along the pipe-girth interfaces. The rotation of the girth is stopped after a preset displacement of the pipes while the force is maintained to consolidate the deformed material and form the joint along the girth-pipe interfaces. Since the girth is only rotated and the pipeline sections remain stationary, the process simplifies the in situ assembly operations and enables the joining of complex configurations. As the melting of pipes and girth is avoided, the formation of harmful intermetallic compounds and deterioration of toughness in the heat affected zone are minimized. A comprehensive numerical model is reported in the present work to analyse the influence of key process variables on the rate of heat generation, resulting temperature field and thermal cycles, and the nature of material flow along the pipe-girth interfaces in girth friction welding of duplex stainless steel pipes. The computed results of thermal cycles and joint shapes are validated with the corresponding experimentally measured results. The results showed a favorable balance of the ferrite and austenite phases, and very little presence of the harmful sigma phases in the recrystallized weld-zone, which is difficult in fusion welding processes of similar materials.

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Section: Theoretical Formulationmentioning

confidence: 80%

Section: Theoretical Formulationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

An investigation on girth friction welding of duplex stainless steel pipes

Kanan

Vicharapu

Pissanti

et al. 2020

Journal of Manufacturing Processes

View full text Add to dashboard Cite

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“…Simulation of rotary friction welding of SUS304 bars was conducted by Jin et al [19] using DEFORM software. By measuring the tensile strength of the samples, it was concluded that the time which is consumed in developing and filling the corona band at the interface can be considered as the minimum time required to complete a welding cycle.…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation of plastic deformation in direct-drive friction welding of AISI 4140 and ASTM A106 steel tubes

Khosrowshahi

Sadeghi

Amir

2020

Archiv.Civ.Mech.Eng

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Direct-drive friction welding of ASTM A106 and AISI 4140 steel tubes has been investigated both experimentally and numerically. A remeshing technique was implemented to accurately simulate highly distorted flashes during the FE simulation. The results revealed that the circumferential thermal expansion led to a higher contact pressure at the inner diameter of the interface and consequently, inner flashes were formed up to 18% larger than the outer ones. The maximum temperature was also located at the outer diameter of the interface in the first moments of the process, then it moved towards the center of the section where there was a balance between the higher slipping rate at the outer section and greater pressure at the inner section of the joint. Validation tests showed the capability of the FE model in terms of temperature, flash cross-section, and axial shortening with the maximum difference of 18.6%.

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“…The fracture study on the tensile tested samples showed a brittle mode. Feng Jin et al [19] did experiments on DDFW of SUS304 in the diameter of 25 mm at 80 MPa. A 2D FEA model was constructed to simulate the thermo-mechanical coupling during welding.…”

Section: Introductionmentioning

confidence: 99%

Experimental study on the effect of silver, nickel and chromium interlayers and upset pressure in joining SS304L-AA6063 alloys through direct drive friction welding process

Murugan

Sathiya

Haq

2020

J Braz. Soc. Mech. Sci. Eng.

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Joining of dissimilar alloys is demanded industrial applications and is effectively possible with the friction welding (FW) process. In this work, SS304L alloy rods were electroplated with silver (Ag), nickel (Ni) and chromium (Cr) and joined with AA6063 at various upset pressures (UP) (18, 21, 24 MPa) through friction welding process. The interlayer produced by the electroplating process was considered as the third element between AA6063 and SS304L during the FW. The results obtained through weld microstructures, fracture images, energy-dispersive X-ray spectroscopy, tensile properties, joint efficiency, Vickers microhardness and Charpy V-notch test of the fabricated dissimilar joints are discussed here. Fracture study showed the dimple fracture. The maximum strength and axial shortening were obtained as 216 ± 8 MPa and 27 mm, respectively. Maximum joint efficiency was achieved for Cr interlayer as 105 ± 4% at 24 MPa UP, which also showed a 1.79 tensile-to-yield (TS/YS) ratio. UP of 24 MPa improved ductile nature of joint. Ag and Ni joints rendered poor elongation. FW of chromium-electroplated specimen gave maximum weld performance than that of others. Ag interlayer at 18 MPa UP showed good hardness. Maximum impact energy observed by Cr at 24 MPa UP was 35 J. The novelty of the work is to frictionally weld the dissimilar metals of ϕ12 mm rods with Ag, Ni, Cr interlayer at welding pressures in view of safety and energy consumption. There were the changes in the microstructure and mechanical properties of joints when the interlayers, UPs changed.

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Numerical simulation based upon friction coefficient model on thermo-mechanical coupling in rotary friction welding corresponding with corona-bond evolution

Cited by 33 publications

References 13 publications

An investigation on girth friction welding of duplex stainless steel pipes

An investigation on girth friction welding of duplex stainless steel pipes

Numerical simulation of plastic deformation in direct-drive friction welding of AISI 4140 and ASTM A106 steel tubes

Experimental study on the effect of silver, nickel and chromium interlayers and upset pressure in joining SS304L-AA6063 alloys through direct drive friction welding process

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