Search results for "Friction welding"
showing 10 items of 71 documents
Strategies for numerical simulation of linear friction welding of metals: a review
2017
Linear friction welding (LFW) is a solid-state joining process used to weld non-axisymmetric components. Material joining is obtained through the reciprocating motion of two specimens undergoing an axial force. During this process, the heat source is determined by the frictional work transformed into heat. This results in a local softening of the material and plays a key role in the onset of the bonding conditions. In this paper, a critical analysis of the different approaches used to simulate the LFW processes is provided. The focus of the paper is the comparison of different modeling strategies and the most relevant outputs available, i.e. temperature, strain and stress distribution, mate…
Mechanical and metallurgical characterization of AA6082-T6 sheet-bulk joints produced through a linear friction welding based approach
2020
In the last decades, new flexible manufacturing processes have been developed to face the demands, by many industrial fields, for highly customized complex functional parts. The peculiar design of these components often overcomes conventional sheet metal and bulk metal forming processes capabilities. In order to face this issue, new hybrid techniques, capable of exploit key advantages of different processes, have to be developed. In this study, a method to obtain sheet-bulk joints, based on the Linear Friction Welding process, is proposed. The feasibility of the technique was investigated through an experimental campaign carried out with varying pressure and oscillation frequency using AA60…
Weld quality prediction in linear friction welding of AA6082-T6 through an integrated numerical tool
2016
Abstract A numerical and an experimental campaign were carried out with varying oscillation frequency and interface pressure. The local values of the main field variables at the contact interface between the specimens were predicted by a Lagrangian, implicit, thermo-mechanical FEM model and used as input of a dedicated Neural Network (NN). The NN, integrated in the FEM environment, was designed in order to calculate both a Boolean output, indicating the occurrence of welding, and a continuous output, indicating the quality of the obtained solid state weld. The analysis of the obtained results allowed three different levels of bonding quality, i.e., no weld, sound weld and excess of heat, to…
Single block 3D numerical model for linear friction welding of titanium alloy
2018
A two-stage approach for the simulation of Linear Friction Welding is presented. The proposed model, developed using the commercial simulation package DEFORM, is 3D Lagrangian, thermo-mechanically coupled. The first phase of the process was modelled with two distinct workpieces, while the remaining phases were simulated using a single-block model. The Piwnik–Plata criterion was set up and used to determine the shifting from the dual object to the single-block model. The model, validated against experimental temperature measurements, is able to predict the main field variables distributions with varying process parameters. Titanium alpha and beta phases evolution during the whole process has…
Residual stress measurement in innovative friction stir welding processes
2017
In recent years, important innovations have been introduced in Friction Stir Welding (FSW) technology such as, for example, the Laser assisted Friction Stir Welding (LFSW) and in-process Cooled Friction Stir Welding (CFSW). Residual stresses have a fundamental role in welded structures because they affect the way to design the structures, fatigue life, corrosion resistance and many other material properties. Consequently, it is important to investigate the residual stress distribution in FSW where, though the heat input is lower compared to traditional welding techniques, the constraints applied to the parts to weld are more severe. The aim of the present work is to verify the capabilities …
Linear friction welding of dissimilar AA6082 and AA2011 aluminum alloys: microstructural characterization and design guidelines
2015
This paper presents the results of an experimental and numerical campaign on Linear Friction Welding of dissimilar AA2011-T8 and AA6082-T6 aluminum alloys. Experimental tests were carried out with constant oscillation amplitude and process time. Varying oscillation frequency, interface pressure, specimen geometry and mutual position were used. Grain size measurements, HV tests and EDX analysis were considered to characterize the microstructure of the joints as a function of the input process parameters. A thermal numerical model was utilized to predict the temperature profiles in the joints during the process. The obtained results allowed the identification of four weld categories: sound jo…
Application of linear friction welding for joining ultrafine grained aluminium
2020
Abstract Ultrafine grained (UFG) materials are of great potential in industry due to their enhanced mechanical strength and other promising features, such as ability to superplastic deformation or excellent corrosion resistance. Nevertheless, one of the main limitations lies in their low thermal stability, which leads to excessive grain growth at elevated temperature. It influences mainly further processes performed at high temperature, such as joining. It causes detrimental problems during conventional fusion welding, as significant grain growth is observed and therefore the advantages as a result of small average grain size disappear. Therefore, the idea of applying solid state joining pr…
Friction based solid state welding techniques for transportation industry applications
2014
Shear coefficient determination in linear friction welding of aluminum alloys
2015
In the present study, a combined experimental and numerical investigation on Linear Friction Welding (LFW) of AA2011-T3 aluminum alloy was carried out in order to find the temperature dependent shear coefficient to be used in a 3D numerical model of the process. Torque, oscillation frequency and pressure were acquired in order to calculate the shear stress at the interface. A numerical thermal model was used to calculate the temperature at the interface between the specimens starting from experimental temperatures acquired through a thermocouple embedded in the LFW specimens. Finally, the calculated shear coefficient was used to model the contact between the two specimens in a dedicated 3D,…