Abstract
A new model of the material flow in rotary friction welding of tubes is proposed. The material flow proposed is based on 3D microcomputer tomography scans of welds performed with tungsten tracers. The tracers indicate a bifurcation of flow into two deformation paths. The material in Path 1 interacts with the weld interface and exhibits large azimuthal flow. The material in Path 2 transitions from axial to primarily radial flow with little or no azimuthal flow. The directional transition in this path is compared to orthogonal machining and equal channel angular pressing. The process to estimate the variables needed to calculate strain and strain rates using the equations from orthogonal machining and equal channel angular pressing is defined. Strain and strain rate in Path 2 are dependent upon feed rate and upset and decrease throughout the welding process. The strain rate is higher than previously reported for rotary friction welding as a result of the deformation model proposed.
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