Numerical simulation of friction welding of aluminium/titanium joints

In this present work concerns, the numerical simulation of Finite Element model was developed for Ti6Al4V alloy/AA6061 T6 alloy parts and experimental validation is carried out under processing conditions using friction welding process. A fully coupled thermo mechanical transient three-dimensional analysis was conducted. Here the temperature distribution on the welded joints is predicted using the analysis tool and the time-temperature profile is also created. The effect of processing parameters on the temperature evolution and axial shortening of friction welded joints were investigated. The result shows that, the temperature at the weld interface reaches the maximum temperature of 468.2 °C within 3.5 s then increases slowly, and finally tends to become uniform across the interface under certain processing conditions. Subsequently, significant axial shortening and fast formation of flash start to happen as the interface temperature becomes more uniform. The measured temperatures and microstructural characteristics agree fairly well with the predicted data. (paper)