Numerical Simulation of the Inertia Friction Welding Process of Dissimilar Materials
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RICTION welding (FW) is one of the highest quality welding processes for solid-state joining similar and dissimilar materials with axisymmetric alignments.[1] Technically, because no melting occurs, friction welding is considered more as a forging technique other than a traditional welding one. The combination of short welding time and direct heat input produces limited heat-affected zone (HAZ), as well as limited growth of voids.[2] The energy input may be in the form of forced linear displacement with linear friction welding or a flywheel’s inertia with continuous rotation. This mechanism was the one being employed for metals as in angular velocity inertia friction welding, which was known as the inertia friction welding (IFW).[3] Friction welding was used to join dissimilar materials together even materials which are difficult to weld using conventional welding techniques. It can also join materials with greatly different metallurgical behavior at or near to the individual alloy’s liquids and solids temperatures.[4] During friction welding of dissimilar metals many problems arise not only due to the different hardness and melting temperature properties, but also due to the possibility of surface interaction producing either brittle intermetallic phases or low melting point eutectics.[5] In the aluminum/steel systems, intermetallic compounds are a major problem. In general, the MEDHAT A. EL-HADEK, Associate Professor, is with the Department of Mechanical Design & Production, Faculty of Engineering at Port-Said, Port-Said University, Port-Fouad, Port-Said 42523, Egypt. Contact e-mail: [email protected] Manuscript submitted January 21, 2014. Article published online August 2, 2014. 2346—VOLUME 45B, DECEMBER 2014
formation of intermetallic phases was being considered undesirable. Recently, Nirmal and Vishal[6] have statistically analyzed the rotary friction welding of steel with varying carbon in workpieces introducing a relationship between the properties of the joints of the dissimilar materials with the time available for the weldment formation. They reported that the longer the incubation period compared to the weldment time, more satisfactory weldments were achieved. However, Fu and Duan[7] found that the duration of the incubation period for intermetallic formation was questionable and that the process should be controlled based on limiting the intermetallic thickness rather than the incubation period. Lately, numerical models were developed that assume coupling between the thermal and mechanical effects.[8–14] Most of these models were considered side to side simulating real experimental conditions. The coupling insures the continuation and consistency through the interface elements. Sluzalec[10] followed by Moal and Massoni[11] developed a finite element method (FEM) code computing the strain and stress fields in the welded components. Similarly, Fu and Duan[7] carried out a coupled deformation and heat flow by finite element analysis (FEA), where these approaches were in agreement with the physical aspects of the
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