Journal of Failure Analysis and Prevention

, Volume 15, Issue 2, pp 300–310 | Cite as

Thermal Stress and Fracture of Friction-Welded Joint Between Pure Ni and Pure Al with Post-weld Heat Treatment

  • Masaaki Kimura
  • Akiyoshi Fuji
  • Yutaro Konno
  • Shinya Itoh
Technical Article---Peer-Reviewed


This paper described the thermal stress and fracture of friction-welded joint between pure nickel (Ni) and pure aluminum (Al) with post-weld heat treatment (PWHT). FEM model of the joint with the NiAl interlayer at the weld interface, of which was generated as the intermediate layer consisting of intermetallic compound, was constructed. Then, FEM thermal elastic–plastic analysis was carried out, and the fracture factor of the joint during the cooling process after PWHT was described from the calculation and experimental results. The calculated thermal stresses at the adjacent region of the weld interface for the joint, due to the difference of material properties between both base metals, occurred at the early stage during the cooling process. However, the thermal stress was relatively low and had a little effect on the joint fracture. All thermal stresses of the joint with the NiAl interlayer width of 200 μm were smaller than those of 20 μm. Actually, the joint fractured between NiAl interlayer and Al side, of which was like as disbonding in the experiment. Hence, one of the main reasons for the fracture of the joint was able to be thought that the bonding strength between NiAl interlayer and Al side decreased with increasing NiAl layer width, because the thermal stress was low. Therefore, the fracture portion will be changed according to combinations of both base metals to be joined for dissimilar friction-welded joints.


Dissimilar joint Friction welding Post-weld heat treatment Interlayer Thermal stress Fracture 



The authors sincerely wish to thank Prof. Dr. You Chul Kim of Japan Welding Research Institute, Osaka University and Dr. Jae-Yik Lee of RIST, Steel Structure Research Laboratory in Republic of Korea for their kindly and aggressive assisting to this study. The authors also wish to thank Prof. Dr. Yoshitaka Iwabuchi, former vice president of Kushiro National College of Technology for his kindly suggesting to this study.


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Copyright information

© ASM International 2015

Authors and Affiliations

  • Masaaki Kimura
    • 1
  • Akiyoshi Fuji
    • 2
  • Yutaro Konno
    • 2
    • 3
  • Shinya Itoh
    • 2
    • 4
  1. 1.Department of Mechanical and System Engineering, Graduate School of EngineeringUniversity of HyogoHimejiJapan
  2. 2.Department of Mechanical Engineering, Faculty of EngineeringKitami Institute of TechnologyKitamiJapan
  3. 3.UACJ CorporationTokyoJapan
  4. 4.Isuzu Motors LimitedTokyoJapan

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