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Advanced Rotary Friction Welding Simulation

Researcher: James Little

Supervisor(s): Hector Basoalto, Richard Turner, Anas Yaghi (the MTC)

 

Rotary Friction Welding has become a popular and convenient joining method within a range of industrial sectors, largely due to the fact that it produces a high-integrity, clean, defect-free joint, when performed properly. The fact that the material is kept below the melting temperature avoids any resoidification cracking and defect forming issues that plague other fusion welding operations. However, the successful envelope for the input welding parameters (applied forging load, initial rotational speed, flywheel energy) to generate a successful weld is unknown. 

A tool to quantify which weld parameters will give an acceptable weld, and which weld parmeters will give an optimal weld, would take a lot of the experimental demand out of the process research. In order to generate this type of tool within an FE software, an understanding needs to be gained in how to quantify the weld integrity. This will come down to better understanding the impacts that strains generated, thermal loads and residual stresses have on the mechanical properties of the material. 

The research project aims to improve the understanding of the impact on mechanical properties of the various welding parameters, allowing for a linked FE and material mechanics model to predict the successful envelope for rotary friction welding. 

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