Abstract
The temperature distributions, microstructure, and mechanical properties of tungsten composite with aluminum alloy friction-welded joints are presented in this paper. The effects of welding parameters on flash diameter, shortening, joint efficiency, microhardness, and microstructure were studied. Empirical temperature models for heating and cooling phases are proposed in this study. The predicted maximum temperatures at the periphery and in the axis of aluminum specimens were close to 550 °C and 480 °C at the interface, respectively. Moreover, the peak temperature in the weld zone was studied analytically. A maximum tensile strength of 234 MPa was reached for the following welding parameters: friction time of 3.5 s and friction force of 12.5 kN. The efficiency of the welded samples decreased after reaching the maximum value, with an increase of friction time and force. Maximum hardness at the interface and the half-radius reached 100 HV and 80 HV in the aluminum alloy joints, respectively. Dynamic recrystallisation areas on the aluminum alloy side were observed. Transmission electron microscopy observations of the microstructure in the aluminum alloy revealed the presence of a high dislocation density compared to the parent material.
Highlights
Rotary friction welding (FRW) is a solid-state welding method in which coalescence of the joining surface is achieved without melting
Shortening of the specimen is not desirable, but it depends on the friction welding parameters, especially on friction force and friction time
The shortening is caused by the fact that the temperature at the weld interface is close to the melting point of 5XXX, which results in a considerable decrease of hardness properties, enabling a very intensive plastic deformation
Summary
Rotary friction welding (FRW) is a solid-state welding method in which coalescence of the joining surface is achieved without melting. FRW uses heat generated from the friction between a moving workpiece and a stationary one to produce the weld. In continuous direct drive friction welding (CDFW), one of the workpieces driven by a motor is rotated continuously at a predetermined speed, while the other is restrained from rotation. Heat is generated as the faying surfaces rub together under pressure. The upsetting pressure must be maintained or increased after rotation ceases to produce a sound weld. In inertia friction welding (IFW), one of the workpieces is connected to a flywheel, and the other is restrained from rotation. The stored energy in the flywheel, decelerated from a preset speed, causes the two faying surfaces to rub together under pressure and produce a weld [1]
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