Experimental and analytical investigation on friction welding dissimilar joints for aerospace applications

Friction welding is a method of joining two materials in solid-state that have a good bonding connection. The materials are eventually joined by continuous acts of forging pressure combined with rotational drives by varying parameters such as friction pressure, forging pressure, friction time, rotation speed and upset time. Low input heat and high contact bonding were the characteristics of this process. In this present work, micro hardness and structural analyses of friction welded joints were investigated exper-imentally, effect of process parameters on properties and temperature distribution were evaluated using ANOVA and were compared with Finite element analysis using ANSYS R16.2. The results were in good agreement with each other. The friction time was 5 s, the rotation speed was 2100 rpm, the friction pres-sure was 80 MPa, and the forging pressure was 84.5 MPa, all of which were optimal process parameters, resulted in sound joints.(c) 2022 THE AUTHORS. Published by Elsevier BV on behalf of Faculty of Engineering, Ain Shams Uni-versity. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).

Automated summary

Friction welding is a solid-state joining method that achieves a strong bond through continuous acts of forging pressure and rotational drives. This study experimentally investigated the microhardness and structural analyses of friction-welded joints, evaluated the effects of process parameters on properties and temperature distribution using ANOVA, and compared the results with finite element analysis using ANSYS R16.2. The optimal process parameters were determined to be a friction time of 5s, rotation speed of 2100rpm, friction pressure of 80MPa, and forging pressure of 84.5MPa.