Abstract
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.
Similar content being viewed by others
References
L. Ke, L.I. Xing, and J.E. Indacochea: Metall. Mater. Trans. B, 2004, vol. 35B, pp. 153–60, DOI: 10.1007/s11663-004-0105-6.
A.L. Biro, B.F. Chenelle, and D.A. Lados: Metall. Mater. Trans. B, 2012, vol. 43B, pp. 1622–37, DOI: 10.1007/s11663-012-9716-5.
M. Mohammadtaheri, M. Haddad-Sabzevar, M. Mazinani, and E.B. Motlagh: Metall. Mater. Trans. B, 2013, vol. 44B, pp. 1–6, DOI: 10.1007/s11663-013-9808-x
M. Akbari, and R.A. Behnagh: Metall. Mater. Trans. B, 2012, vol. 43B, pp. 1177–86, DOI: 10.1007/s11663-012-9682-y.
Y. Zhu, Y. Guo, and L. Yang: Metall. Mater. Trans. B, 2013, vol. 44B, pp. 396–405, DOI: 10.1007/s11663-013-9795-y.
S.K. Nirmal, and S.S. Vishal: Int. J. Adv. Manuf. Technol., 2011, vol. 57, pp. 957–67, DOI: 10.1007/s00170-011-3361-z.
L. Fu, and L.Y. Duan: Weld. J., 1998, vol. 77, pp. 202–7.
L. Wang, M. Preuss, P.J. Withers, G. Baxter, and P. Wilson: Metall. Mater. Trans. B, 2005, vol. 36B, pp. 513–23, DOI: 10.1007/s11663-005-0043-y.
R. Turner, R.M. Ward, R. March, and R.C. Reed: Metall. Mater. Trans. B, 2012, vol. 43B, pp. 186–97, DOI: 10.1007/s11663-011-9563-9.
A. Sluzalec: Int. J. Mech. Sci., 1990, vol. 32, pp. 467–78, DOI: 10.1016/0020-7403(90)90153-A.
A. Moal, and E. Massoni: Eng. Comput., 1995, vol. 12, pp. 497–512, DOI: 10.1108/02644409510799730.
M. Bellet, F. Decultieux, M. Menai, F. Bay, C. Levaillant, JL. Chenot, P. Schmidt, and L. Svensson: Metall. Mater. Trans. B, 1996, vol. 27B, pp. 81–99, DOI: 10.1007/BF02915080.
L. D’Alvise, E. Massoni, and S.J. Walløe: J. Mater. Process. Technol., 2002, vol. 125, pp. 387–91, DOI: 10.1016/S0924-0136(02)00349-7.
K.I. Ahmed: Ph.D. Dissertation at Jawaharlal Nehru Technological University, 2012, http://hdl.handle.net/10603/3467.
V. Balasubramanian, Y. Li, T. Stotler, J. Crompton, N. Katsube, and W. Soboyejo: Mater. Manuf. Proc., 1999, vol. 14, pp. 755–73, DOI: 10.1080/10426919908914867.
C.J. Bennett, T.H. Hyde, and E.J. Williams: Proc. Inst. Mech. Eng., 2007, vol. 221, pp. 275–84, DOI: 10.1243/14644207JMDA154
The Egyptian Metallurgical Industries Company (E.Js.H.Co) at Helwan, Egypt http://www.micor.com.eg/Default.aspx. Accessed May 2013.
M. El-Hadek: Int. J. Comput. Meth. Eng. Sci. Mech., 2009, vol. 10, 224–230, DOI: 10.1080/15502280902795086
M.A. El-Hadek, and S. Kaytbay: Strain, 2009, vol. 45, pp. 506–15, DOI: 10.1111/j.1475-1305.2008.00552.x.
S.-Y. Chang, C.-F. Chen, S.-J. Lin, and T.Z. Kattamis: Acta. Mater., 2003, vol. 51, pp. 6291–302, DOI:10.1016/S1359-6454(03)00462-2.
Electrical properties, International Annealed Copper Standard by the International Electro technical Commission (IACS) in terms of the following properties at 20 °C, 1913.
G. Weng: Int. J. Eng. Sci., 1984, vol. 22, pp. 845–56, DOI: 10.1016/0020-7225(84)90033-8.
S. Raymond: Physics for Scientists and Engineers with Modern Physics, 3rdEd, Saunders College Publishing, Rochester, 1990
L.-I. Tong, and C.-T. Su: J. Qual. Reliab. Eng. Int., 1997, vol. 13, pp. 25–34, DOI: 10.1002/(SICI)1099-1638(199701)13:1<25::AID-QRE59>3.0.CO;2-B.
J.A. Ghani, I.A. Choudhury, and H.H. Hassan: J. Mater. Process. Technol., 2004, vol. 145, pp. 84–92, DOI: 10.1016/S0924-0136(03)00865-3.
L.I. Tong, C.T. Su, and C.H. Wang: Int. J. Qual. Reliab. Manag., 1997, vol. 14, pp. 367–80, DOI: 10.1108/02656719710170639.
N. Logothetis, and A. Haigh: J. Qual. Reliab. Eng. Int., 1988, vol. 4, pp. 159–69, DOI: 10.1002/qre.4680040211.
D. Lazarević, M. Madić, P. Janković, and A. Lazarević: J. Tribol. Ind., 2012, vol. 34 pp. 68–73, DOI: 0351-16421202068L.
Acknowledgment
The author would like to thank the Egyptian Suez Canal Authority for their help and assistant during the course of this study.
Author information
Authors and Affiliations
Corresponding author
Additional information
Manuscript submitted January 21, 2014.
Rights and permissions
About this article
Cite this article
El-Hadek, M.A. Numerical Simulation of the Inertia Friction Welding Process of Dissimilar Materials. Metall Mater Trans B 45, 2346–2356 (2014). https://doi.org/10.1007/s11663-014-0148-2
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11663-014-0148-2