Abstract
The orbital friction welding of eutectoid steel bars is investigated using experimental and numerical analyses. By a three-dimensional (3-D) coupled thermomechanical finite element (FE) model, the temperature profile, axial shortening, and flash formation at the joint interface are analyzed. With a thermal phase transformation FE model, the volume fractions of the final microstructure constituents and the size of the heat-affected zone (HAZ) are also predicted. For use in the models, the frictional heat generation is estimated by inverse heat-transfer analysis. The predicted HAZ width, upset, thermal history, and final microstructure are verified successfully on the experimental measurements.
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