Development of Continuous Drive Friction Welding (CDFW) model in ABAQUS for AA 6061-T6 alloy to verify experimental results and to predict behavior of similar and dissimilar alloys AA 6061-5083

Abstract

Continues drive friction welding, a type of rotary friction welding, is a solid state welding process in which similar materials and dissimilar materials are welded together. During the process one part is rotated with a particular RPM and other part is moved with the help of axial force or pressure towards the rotating rod. First both surfaces of rod are rubbed to generate heat which should be below the melting point and then pressure or axial force is applied that moves the rod into the rotating rod and cause a weld. The temperature generated during fusion of rods, is the main parameter which is less than melting point of materials but greater than that at which crystallization of newly formed crystals during mixing of similar and dissimilar materials takes place. The fusion temperature is important for the weld strength. Experimentally temperature with respect to varying time, radius of rods, RPM can be measured using thermocouples. So in this research, a 3-D model is developed of Continues drive friction welding in ABAQUS environment to observe the change of temperature with respect to time and other parameters for similar AA 6061-T6 and dissimilar AA 1050 with AISI 304 Austenitic steel and AA 6061-T6 with AA 5083 H111. Experimental results and simulated results of temperature with respect to other parameters and material properties i-e Von Mises of simulated results are compared which are less than 10 percentage errors. Results obtained were better in ABAQUS environment as compared to COMSOL in which 2-D analysis was done.