Numerical Simulation of the Inertia Friction Welding Process of Dissimilar Materials

Three-dimensional axisymmetric finite element analyses have been performed to analyze the coupled thermo-mechanical oscillatory transient problem of friction welding of two dissimilar hollow cylinders. The analysis included the effect of conduction and convection heat transfer implementing three independent variables specifically the welding time, the rotational velocity, and the thrust pressure. Experimental evaluation of the non-linear copper and Aluminum 6061 stress-strain responses, the thermal conductivities, and the specific heat coefficients were conducted using an environmental-controlled compartment for at least four different temperatures. These results were incorporated in the finite element model calculating a real joint transient temperature distribution and a full field view of the residual stresses in weldment. Variables of angular rotational velocity of (200, 400, and 600 rpm), thrust pressure of (10E5, 10E6, and 10E7 Pa), and total welding time of (1, 2, and 4 seconds) were used in the model simulation. The optimum welding conditions were selected using Taguchi method. Finally, the deformation shape predicted by the finite element simulations was compared to the deformations obtained by the experimental results.