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Finite Element Modeling of the Inertia Friction Welding of Dissimilar High-Strength Steels

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Abstract

Finite element (FE) process modeling of inertia friction welding between dissimilar high-strength steels, AerMet® 100 and SCMV, has been carried out using the DEFORM™-2D (v10.0) software. This model was validated against experimental data collected for a test weld performed between the materials; this included process data such as upset and rotational velocities as well as thermal data collected during the process using embedded thermocouples. The as-welded hoop residual stress from the FE model was also compared with experimental measurements taken on the welded component using synchrotron X-ray and neutron diffraction techniques. The modeling work considered the solid-state phase transformations which occur in the steels, and the trends in the residual stress data were well replicated by the model.

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Acknowledgments

The authors would like to thank Rolls-Royce plc. The views expressed in this paper are those of the authors and not necessarily those of Rolls-Royce plc. The current study has been carried out under the PROMOTE project funded by The Technology Strategy Board, Rolls-Royce plc and Wilde Analysis Ltd. The Technology Strategy Board is a business-led executive nondepartmental public body, established by the government. Its mission is to promote and support research into, and development and exploitation of, technology and innovation for the benefit of the UK business, to increase economic growth and improve the quality of life. It is sponsored by the Department for Innovation, Universities and Skills (DIUS). Please visit www.innovateuk.org for further information.

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Authors and Affiliations

  1. Department of Mechanical, Materials and Manufacturing Engineering, University of Nottingham, Nottingham, NG7 2RD, UK

    C. J. Bennett (Lecturer), P. H. Shipway (Professor) & T. H. Hyde (Professor)

  2. School of Metallurgy and Materials, University of Birmingham, Edgbaston, Birmingham, B15 2TT, UK

    M. M. Attallah (Lecturer)

  3. School of Materials, The University of Manchester, Grosvenor Street, Manchester, M1 7HS, UK

    M. Preuss (Professor)

  4. Rolls-Royce plc, PO Box 31, Derby, DE24 8BJ, UK

    S. Bray (Engineering Specialist)

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  1. C. J. Bennett
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  2. M. M. Attallah
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  3. M. Preuss
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  4. P. H. Shipway
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  5. T. H. Hyde
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  6. S. Bray
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Correspondence to C. J. Bennett.

Additional information

Manuscript submitted September 5, 2012.

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Bennett, C.J., Attallah, M.M., Preuss, M. et al. Finite Element Modeling of the Inertia Friction Welding of Dissimilar High-Strength Steels. Metall Mater Trans A 44, 5054–5064 (2013). https://doi.org/10.1007/s11661-013-1852-2

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