Experimental and FEM Studies of Continuous Drive Friction Welding of Ferritic Spheroidal Graphite Cast Iron

Abstract

Experimental and FEM studies of the friction welding process of spheroidal graphite cast iron (SGCI) are presented. A coupled thermal and mechanical 2.5 D FEM model was used to simulate the continuous drive friction welding (CDFW) process. The FE model predicted the peak temperature of the joint, effective stress, axial shortening, and the weld flash size. Additionally, the friction force on the axial shortening of specimens was studied. The peak temperatures were measured both on the axis and at the surface of the specimen. The predicted maximum temperatures in the axis, ½ radius, and 2 mm from the surface of the sample amounted to 1162 °C, 1177 °C, and 1061 °C, respectively. The maximum temperature of the spheroidal graphite cast iron joint was below the melting temperature of the base material (~1350 °C). The predicted temperature curves, outbursts, and shortening of welded elements indicated a good match with real models.