Prediction of residual stress within linear friction welds using a computationally efficient modelling approach. (5th February 2018)

• Record Type: Journal Article
• Authors: Bühr, Clément; Ahmad, Bilal; Colegrove, Paul A.; McAndrew, Anthony R.; Guo, Hua; Zhang, Xiang
• Is Part Of: Materials & design. Volume 139(2018)
• Page Start: 222
• Page End: 233
• Publication Date: 2018-02-05
• Subjects: Linear friction welding -- Titanium -- Residual stress -- Modelling -- Experiments; Materials -- Periodicals; Engineering design -- Periodicals; Matériaux -- Périodiques; Conception technique -- Périodiques; Electronic journals; 620.11
• DOI: 10.1016/j.matdes.2017.11.013
• Languages: English
• ISSNs: 0264-1275

Abstract

Abstract: Modelling the mechanical mixing occurring at the interface of a linear friction weld (LFW) is complex, making it difficult to study the development of residual stresses within real engineering workpieces. To address this, a sequentially-coupled numerical model of a Ti-6Al-4V LFW was developed, bypassing the modelling of the oscillations by applying the heat at the weld interface and sequentially removing rows of elements to account for the burn-off. Increasing the rubbing velocity was found to numerically increase the peak of residual stress while narrowing the distribution. Only small changes arose from increasing the applied pressure or changing the oscillation direction. Predictions suggested a strong correlation between the phase 3 temperature profile and the residual stress field subsequently created. Validation against neutron diffraction and contour method are also presented. This approach provides a computationally efficient technique to study the residual stress development within large 3D structures. Graphical abstract: Highlights: The modelling approach predicts residual stresses within linear friction welds with notably reduced computational time. Increasing the rubbing velocity increased the peak residual stress and narrowed the band of tensile residual stress. The residual stress distribution is strongly affected by the thermal gradient of the equilibrium temperature field. High weld interface temperature enlarges the band of tensile residual stress.