A computational modeling of fully friction contact-interaction in linear friction welding of Ni-based superalloys

Abstract

A three-dimensional coupled thermo-mechanical model was developed to simulate the linear friction welding (LFW) of same or dissimilar Ni-based superalloys. Full friction contact-interaction for two deformable workpieces rubbing against each other was considered using plastic/plastic friction pair model. Numerical simulated results have been well validated by experimental measured data. Owing to the inherent motion mechanism of LFW, interfacial heat flow varied with time periodically, resulting in the periodic evolution of interface temperature. The distribution of stress field at stationary side alternated dynamically with respect to that at oscillatory side. During LFW of GH4169 to FGH96 superalloys, more heat flowed into the GH4169 superalloy, which resulted in greater temperature gradient than that at side of FGH96 superalloy. More softened materials were extruded out from interface at GH4169 side owing to their better flow property. Peak stress near the interface of GH4169 superalloy side was higher than that at FGH96 side. Additionally, the characteristics of modeling of LFW based on plastic/plastic friction pair model were investigated by performing numerical simulations for LFW experimental phenomena.