Fig. 1
Rotary friction welding process.
Fig. 2
Welding parameters for CDFW. [1]
Table 1
Al6061 material properties for phase-change simulation. [16]
| Property | Value |
|---|---|
| Ttrans [K] | 925.15 |
| δT [K] | 50 |
| Δhf [kJ/kg] | 380 |
| ρsolid [kg/m3] | 2705 |
| ρliquid [kg/m3] | 2415 |
| Cp,solid [J/kg·K] | 870 |
| Cp,liquid [J/kg·K] | 1170 |
| κsolidus [W/m·K] | 66.5 |
| κliquid [W/m·K] | 90 |
Fig. 3
2D axisymmetric geometry of the workpiece.
Table 2
FEM boundary conditions.
| Model | Feature | Boundary Condition |
|---|---|---|
| Solid Mechanics | The central axis of the parts | Axial Symmetry |
| The outer surfaces of the parts | Free to deform | |
| The Entire model | Zero initial displacement | |
| The rotating part | Rigid motion suppression | |
| The end of the fixed part | Axial load | |
| Heat Transfer | T = 305 K | Initial temperature |
| The central axis of the parts | Axial symmetry | |
| The outer surfaces of the parts | Heat flux according to q0 = h · (Text − T) | |
| Welding Parameters | Rotation | 0 s to tf = rotation speed, otherwise zero |
| Pressure | 0 s to tf = applied pressure, otherwise zero |
Fig. 4
a) the number of elements and fineness of the mesh and, b) convergence plot of the size of elements.
Fig. 5
The two parts to be welded before welding.
Table 3
Chemical composition in weight percent of Al6061.
| Element | Si | Fe | Cu | Mn | Mg | Zn | Cr | Ti | Al |
|---|---|---|---|---|---|---|---|---|---|
| Wt% | 0.75 | 0.5 | 0.5 | 0.15 | 0.9 | 0.03 | 0.03 | 0.05 | Rest |
Table 4
CDFW process parameters.
| Process Parameter | Value / range |
|---|---|
| Rotational Speed (rpm) | 2000 |
| Friction Pressure (MPa) | 21 |
| Friction time (s) | 4, 5, 6, 9, 10, 12 |
Fig. 6
Variation of the phase change coefficient as a function of the temperature of aluminum 6061.
Fig. 7
Variation in the specific heat capacity of AA6061 as a function of temperature.
Fig. 8
Variation in the density of AA6061 as a function of temperature.
Fig. 9
Variation in the thermal conductivity of AA6061 as a function of temperature.
Fig. 10
Modeled process parameters for tf = 10 s.
Fig. 11
The temperature profile for the 12 s friction time.
Fig. 12
Temperature profiles for different friction times; 4, 5, and 6 s, respectively.
Fig. 13
The temperature profile for 9 and 10 s friction times.
Fig. 14
Welding flash formation at different friction times; these are 4, 5, 6, 9, and 10 s, respectively.
Fig. 15
Temperature profile at the contact zone at t = 0 s.
Fig. 16
Temperature profile at the contact zone at t = 1 s.
Fig. 17
Temperature profile at the contact zone at t = 5 s.
Fig. 18
The temperature profile at the contact zone at t = 10 and 11 s.