Experimental and Numerical Thermomechanical Analysis of Hybrid Friction Welding of Commercially Pure Copper Bars

Abstract

Friction welding is a solid-state welding process accomplished by direct conversion of mechanical energy into the thermal energy at the interface of workpieces without melting. The friction welding process can be controlled through different parameters, such as angular velocity, pressure, temperature, stress and strain distribution, and so on. The welding machine design as well as welded part quality could be significantly improved by understanding and optimizing the process parameters. Hybrid friction welding (HFW) is introduced as one of the rotary friction welding processes that benefits advantages of continuous drive friction welding and inertia friction welding, while attempts have been made to eliminate the disadvantages of old friction welding processes. In this study, three-dimensional thermomechanical simulation of hybrid rotary friction welding of equal diameter copper workpieces has been carried out and the effect of various parameters, especially the pressure, on the thermomechanical behavior and the shape of welded zone has been investigated.