Skip to main content
SpringerLink
Log in

Numerical simulation of rotary friction welding of Ti-6Al-4V tubes

  • Research Paper
  • Published:
Welding in the World Aims and scope Submit manuscript

Abstract

A two-dimensional model of continuous drive friction welding (CDFW) of Ti-6Al-4V tubes was developed using the ABAQUS modeling software. The effect of interface temperature on frictional behavior during welding was investigated, where non-linear temperature-dependent material properties were considered. The effects of rotational speed and friction pressure on the temperature field, flash morphology, interface temperature, and axial shortening of the joints were studied. Results show that the interface temperature rises rapidly early in the process, to reach a plateau at 1270 °C. For a constant welding time, the temperature gradients and axial shortening of the joints increase with increasing the rotating speed and friction pressure; the steady-state temperature of the interface increases with the increase of rotational speed and decreases with the increase of axial pressure; following welding, the expelled material in the form of a flash curls on the outer wall of the tube, while being symmetrical about the welding interface. Modeling results were well validated with CDFW experiments.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16

Similar content being viewed by others

Data availability

The processed data required to reproduce these fndings cannot be shared at this time as these data form part of an ongoing study.

References

  1. Hong Q, Guo P, Zhou W (2022) Forming technique and app-lication of titanium alloy, titanium industry progress. 39:27–32(in Chinese). https://doi.org/10.13567/j.cnki.issn1009-9964.2022.05.010

  2. Chen YC, Nakata K (2009) Microstructural characterization and mechanical properties in friction stir welding of aluminum and titanium dissimilar alloys. Mater Des 30:469–474. https://doi.org/10.1016/j.matdes.2008.06.008

    Article  CAS  Google Scholar 

  3. Tao BH, Li Q, Zhang YH (2015) Effects of post-weld heat treatment on fracture toughness of linear friction welded joint for dissimilar titanium alloys. Mater Sci Eng A 634:141–146. https://doi.org/10.1016/j.msea.2015.03.003

    Article  CAS  Google Scholar 

  4. Zhang CQ, Robson JD, Prangnell PB (2016) Dissimilar ultra-sonic spot welding of aerospace aluminum alloy AA2139 to titanium alloy TiAl6V4. J Mater Process Technol 231:382–388. https://doi.org/10.1016/j.jmatprotec.2016.01.008

    Article  CAS  Google Scholar 

  5. Wang KS, Zhang XL, Shen Y (2008) Study on micro-structure and morphology of TC4 titanium alloy joined by friction stir welding. Rare Metal Mater Eng 37:2045–2048, (in Chinese). https://doi.org/10.3321/j.issn:1002-185X.2008.11.038

    Article  CAS  Google Scholar 

  6. Torsakul S, Kongsib J, Brezing AN (2015) The influence of annealing on material properties of rotary-friction welded steel-parts. IEEM:170–174. https://doi.org/10.1109/ieem.2015.7385630

  7. Zhang K, Zhang W, Brune R (2021) Numerical simulation and experimental measurement of pressureless sintering of stainless steel part printed by Binder Jetting Additive Manufacturing. Addit Manuf 47:102330. https://doi.org/10.1016/j.addma.2021.102330

    Article  CAS  Google Scholar 

  8. Turner R, Gebelin JC, Ward RM (2011) Linear friction welding of Ti-6Al-4V: modelling and validation. Acta Mater 59:3792–3803. https://doi.org/10.1016/j.actamat.2011.02.028

    Article  CAS  Google Scholar 

  9. Li WY, Ma TJ, Li JL (2010) Numerical simulation of linear friction welding of titanium alloy: effects of processing parameters. Mater Des 31:1497–1507. https://doi.org/10.1016/j.matdes.2009.08.023

    Article  CAS  Google Scholar 

  10. Turner RP, Howe D, Thota B (2016) Calculating the energy required to undergo the conditioning phase of a titanium alloy inertia friction weld. J Manuf Process 24:186–194. https://doi.org/10.1016/j.jmapro.2016.09.008

    Article  Google Scholar 

  11. Ma TJ, Li WY, Xu QZ (2007) Linear friction welding of Ti-6Al-4V alloy: microstructure characterization. IWJC-Korea 582-582:405–408. https://doi.org/10.4028/www.scientific.net/MSF.580-582.405

    Article  Google Scholar 

  12. Li TP, Zhang YY, Zhang HJ (2021) Influence of rotation speed on temperature distribution and microstructure of TC4 friction welded joint. Hot Working Technology 50:33–36. (in Chinese) https://doi.org/10.14158/j.cnki.1001-3814.20202228

    Article  Google Scholar 

  13. Chen HY, Fu L, Zhang WY (2015) Radial distribution characteristics of microstructure and mechanical properties of Ti-6Al-4V butt joint by rotary friction welding. Acta Metall Sin 28:1291–1298. https://doi.org/10.1007/s40195-015-0325-6

    Article  CAS  Google Scholar 

  14. Jin F, Rao HD, Wang Q (2023) Heat-pattern induced non-uniform radial microstructure and properties of Ti-6Al-4V joint prepared by rotary friction welding. Mater Charact 195. https://doi.org/10.1016/j.matchar.2022.112536

  15. Senkov ON, Mahaffey DW, Semiatin SL (2014) Inertia friction welding of dissimilar superalloys Mar-M247 and LSHR. METALL MATER TRANS A 45:5545–5561. https://doi.org/10.1007/s11661-014-2512-x

    Article  CAS  Google Scholar 

  16. Senkov ON, Mahaffey DW, Tung DJ (2017) Efficiency of the inertia friction welding process and its dependence on process parameters. METALL MATER TRANS A 48:3328–3342. https://doi.org/10.1007/s11661-017-4115-9

    Article  CAS  Google Scholar 

  17. Li WY, Wang FF (2011) Modeling of continuous drive friction welding of mild steel. Mater Sci Eng A 528:5921–5926. https://doi.org/10.1016/j.msea.2011.04.001

    Article  CAS  Google Scholar 

  18. Moal A, Massoni E (1995) Finite element simulation of the inertia welding of two similar parts. Eng Comput 12:497–512. https://doi.org/10.1108/02644409510799730

    Article  Google Scholar 

  19. Maalekian M, Kozeschnik E, Brantner HP (2008) Comparative analysis of heat generation in friction welding of steel bars. Acta Mater 56:2843–2855. https://doi.org/10.1016/j.actamat.2008.02.016

    Article  CAS  Google Scholar 

  20. Bennett CJ, Attallah MM, Preuss M (2013) Finite element modeling of the inertia friction welding of dissimilar high-strength steels. Metall Mater Trans A Phys Metall Mater Sci 44A:5054–5064. https://doi.org/10.1007/s11661-013-1852-2

    Article  CAS  Google Scholar 

  21. Lu YL, Jiao SH, Zhou XT (2012) Study on hot deformation behavior of TC4 titanium alloy, symposium on materials processing and interfaces from 141st TMS annual meeting and exhibition. 1:841–848. https://doi.org/10.1002/9781118356074.ch105

  22. By H, Cg L, Lk S (2006) China materials engineering canon. Nonferrous materials and engineering (part 1). vol. 4. Chemical Industry Press, Beijing, p 585 (in Chinese)

    Google Scholar 

  23. Liu P (2019) Research on flash formation mechanism during rotary friction welding of TC4 titanium alloy. Northwestern Polytechnical University (in Chinese)

    Google Scholar 

Download references

Acknowledgements

This study was supported by the National Key R&D Program of China “Development and application of high-performance titanium alloy tubes for energy well drilling in harsh environments” (2021YFB3700804) and the Northwestern Polytechnical University analysis and testing center (2021T013).

Author information

Authors and Affiliations

  1. State Key Laboratory of Solidification Processing, Shanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, China

    Yaxin Xu, Wenxue Chen, Wenya Li & Xiawei Yang

Authors
  1. Yaxin Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Wenxue Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Wenya Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Xiawei Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Wenya Li.

Ethics declarations

Competing interests

The authors declare no competing interests.

Additional information

Publisher’s Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Xu, Y., Chen, W., Li, W. et al. Numerical simulation of rotary friction welding of Ti-6Al-4V tubes. Weld World 67, 2671–2681 (2023). https://doi.org/10.1007/s40194-023-01597-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40194-023-01597-1

Keywords

Search

Navigation