Thermomechanical modelling for the linear friction welding process of Ni-based superalloy and verification

Okeke, Saviour I.; Harrison, Noel M.; Tong, Min

doi:10.1177/1464420719900780

Cited by 5 publications

(18 citation statements)

References 76 publications

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“…Materials with less strength and hardness tend to plastically deform under the dynamic force and high temperature during friction welding. 27–31 Figures 8(b) and 6(c) indicate the microstructures of the weld flash which is formed during welding on the IN718 side and on the SCM440 side, respectively. As can be seen from the macrostructures, the weld flash on the IN718 side is not noticeable compared to the SCM440 side.…”

Section: Resultsmentioning

confidence: 99%

Evaluation of the mechanical properties of Inconel 718 to SCM 440 dissimilar friction welding through real-time monitoring of the acoustic emission system

Kong

Cheepu²,

Lee

2021

Proceedings of the Institution of Mechanical Engineers, Part L:

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Friction welding was chosen for its versatility in the joining of dissimilar materials with high quality. The aim of this study is to determine the optimal welding conditions for attaining quality joints by using online monitoring of acoustic emission system signals. During friction welding, the formation of cracks, defects, or any abnormalities in the joining process which have a detrimental effect on the joints quality was identified. The most widely used materials in the aerospace industry—Inconel 718 and molybdenum steel—were joined by friction welding. The precision of the joints, internal defects, and quality are major concerns for aerospace parts. The results of the present research determined the optimal welding conditions for high tensile strength by nondestructively inducing acoustic emission signals. During friction time and upset time periods, the typical waveforms and frequency spectrum of the acoustic emission signals were recorded, and their energy level, average frequency, cumulative count, and amplitude were analyzed. Both cumulative count and amplitude were found to be useful parameters for deriving the optimal welding conditions. In the initial stage of friction welding, a very high voltage of continuous form was generated with frequency characteristics of 0.44 MHz and 0.54 MHz. The signals generated during the upset stage had a low voltage, but a very high frequency of 1.56 MHz and 1.74 MHz with a burst-type signal. The amplitude of the signal generated for the optimally welded joints was about 100 dB at the friction time and about 45 dB at the upset time.

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Section: Resultsmentioning

confidence: 99%

Evaluation of the mechanical properties of Inconel 718 to SCM 440 dissimilar friction welding through real-time monitoring of the acoustic emission system

Kong

Cheepu²,

Lee

2021

Proceedings of the Institution of Mechanical Engineers, Part L:

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show abstract

“…The results obtained by Popov and coworkers indicate that the adhesive contact of flat bodies can clearly depend on the macroscopic shape of the contact zone [17]. Therefore, the shape of the contact zone of interacting bodies formed as a result of LFW can influence the strength characteristics of the welded joint [7].…”

Section: Introductionmentioning

confidence: 99%

“…In modern engineering practice, two modifications of friction welding technology are used Linear Friction Welding (LFW) and Friction stir welding (FSW) [1][2][3][4][5][6][7][8][9][10][11].…”

Section: Introductionmentioning

confidence: 99%

“…LFW makes it possible to obtain strong joining of materials at the contact interface plane of moved bodies through the heat generation at friction and material particle transport between contacting bodies [5][6][7]. LFW is a manufacturing process used primarily within the aviation industry, where high integrity welds are required in aero-engine production [5].…”

Section: Introductionmentioning

confidence: 99%

“…LFW is a manufacturing process used primarily within the aviation industry, where high integrity welds are required in aero-engine production [5]. This technology is used for welding critical parts of power equipment, such as bladed-disk (blisk) of turbines [7].…”

Section: Introductionmentioning

confidence: 99%

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Modeling of Titanium Alloys Plastic Flow in Linear Friction Welding

et al. 2021

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The article presents the results of the analysis of the plastic flow of titanium alloys in the process of the Linear Friction Welding (LFW). LFW is a high-tech process for joining critical structural elements of aerospace engineering from light and high-temperature alloys. Experimental studies of LFW modes of such alloys are expensive and technically difficult. Numerical simulation was carried out for understanding the physics of the LFW process and the formation laws of a strong welded joint of titanium alloys. Simulation by the SPH method was performed using the LS DYNA software package (ANSYS WB 15.2) and the developed module for the constitutive equation. The new coupled thermomechanical 3D model of LFW process for joining structural elements from alpha and alpha + beta titanium alloys was proposed. It was shown that the formation of a welded joint occurs in a complex and unsteady stress-strain state. In the near-surface layers of the bodies being welded, titanium alloys can be deformed in the mode of severe plastic deformation. A deviation of the symmetry plane of the plastic deformation zone from the initial position of the contact plane of the bodies being welded occurs during a process of LFW. Extrusion of material from the welded joint zone in the transverse direction with respect to the movement of bodies is caused by a pressure gradient and a decrease in the alloy flow stress due to heating. The hcp-bcc phase transition of titanium alloys upon heating in the LFW process necessitates an increase in the cyclic loading time to obtain a welded joint.

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Dissolution of delta phase in Ni-based superalloy during linear friction welding: integrated multiphysics computational process modelling

Okeke

Harrison

Tong

2021

Int J Adv Manuf Technol

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Linear friction welding (LFW) is an increasingly popular solid-state joining method for challenging applications such as integrated blade disk of aero-engines. However, the influence of friction-generated heat on the material microstructural evolution, material deformation and resultant mechanical performance of the manufactured components is not well understood. A novel integrated multiphysics computational modelling is presented for predicting the component-scale microstructural evolution of IN718 alloy during LFW. A modified time-temperature equivalence formulation was implemented for predicting the evolution of the δ phase, which was coupled with thermomechanical modelling of the LFW process. There is reasonably good agreement between the computational modelling results of this paper and the experimental results from the literature in terms of δ phase volume fraction and weld temperature. The integrated multiphysics computational modelling predicts the influence of process parameters on thermomechanical and microstructural processes of IN718 LFW. By systematically analysing the influence of 10 different LFW process parameter configurations, the friction pressure was identified as the most influential process parameter determining the extent of δ phase dissolution and weld temperature during LFW.

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Thermomechanical modelling for the linear friction welding process of Ni-based superalloy and verification

Cited by 5 publications

References 76 publications

Evaluation of the mechanical properties of Inconel 718 to SCM 440 dissimilar friction welding through real-time monitoring of the acoustic emission system

Evaluation of the mechanical properties of Inconel 718 to SCM 440 dissimilar friction welding through real-time monitoring of the acoustic emission system

Modeling of Titanium Alloys Plastic Flow in Linear Friction Welding

Dissolution of delta phase in Ni-based superalloy during linear friction welding: integrated multiphysics computational process modelling

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