3D rigid viscoplastic FE modelling of continuous drive friction welding process

With torsional friction being introduced into the calculation of heat generation and deformation, a 3D rigid viscoplastic FE (finite element) model was established to describe the continuous drive friction welding process. In this model, the workpiece was treated as a deformable body with rigid viscoplastic incompressible material. The friction stress was calculated using Coulomb friction law and shear friction law at different stages of friction welding process respectively. The model simulated two continuous drive friction welding cases by performing coupled thermal and mechanical analyses. Simulations successfully predict the thermal history of the joint as well as deformation rate and final geometries. Meanwhile, the possibility of defect occurrence is also obtained. Experiments on continuous drive friction welding of GH4169 superalloy rod were carried out. The temperature history and the final geometry of the welded joint were measured and compared with the calculated results, which show a good agreement between them.