3D Modelling of Flash Formation in Linear Friction Welded 30CrNiMo8 Steel Chain

Abstract

Linear friction welding (LFW) is a solid-state welding process that has been thoroughly investigated for chain welding in recent years in order to replace the currently in use Flash Butt Welding (FBW) process. Modelling has proven to be an indispensable tool in LFW, thus providing necessary insight to the process, regardless of its final application. This article describes a 3D model developed in the commercial software DEFORM to study the LFW process of 30CrNiMo8 high strength steel in the Hero chain. Hence, a weakly coupled thermal and mechanical model were used, by means of the process experimental input such as displacement histories. The flash morphology and intervening mechanisms were analyzed. A thermal evaluation of different regions in the studied geometry was considered, and a correlation of the modeled and experimental width of the extrusion zone was established.

Recent Achievements in Rotary, Linear and Friction Stir Welding of Metals Alloys

“…In more detail, the contributions have concerned the following topics.The effect of cold rolling performed after friction stir welding (FSW) on the mechanical properties and formability of joints in AA5754-H114 aluminum alloy [1].The microstructure evolution of the welded joints of AA6082-T6 obtained using the bobbin friction stir welding process with a focus on grain refinement [2].The characteristic features of the entry and exit defects in the weld structure and formation mechanism of them during the BFSW process. The issue was investigated using stacked layers of multi-colored plasticine for the material flow detection [3].The thermo-structural analysis of material behavior, material flow, and defect generation during the friction stir butt-welding of 5083-O sheets [4].The characterization of the dissimilar friction stir weld of Ti-6242 S and Ti-54M in terms of microstructure, microhardness, fracture morphology, and material migrating from the retreating (RET) side to the advancing (ADV) one [5].The characterization of the interface of friction stir lap welding joints of 6082-T6 aluminum alloy and Q235A steel [6].The investigation of the microstructure evolution and properties response of a friction-stir-welded copper-chromium-zirconium alloy [7].The study of the influence of the process parameters on the vertical force generated during friction stir welding of AA6082-T6 aluminum alloy sheet blanks [8].The role of mechanical connection in friction stir keyholeless spot welding of AZ31B Mg alloy, Mg99.50, DP600, and non-zinc-coated DP600 lap welding [9].The application of a fully coupled thermo-mechanical model together with an enhanced friction law for the simulation of an FSW process with a cylindrical threaded pin tool [10].The identification of the chemical composition of etchant reagents for metallographic examination of the friction-stir welded A6082-T6 alloy [11].The study of an advanced meshfree computational framework to be used for the determination of optimal process parameters for the friction stir welding of an AA6061-T6 butt joint [12].The numerical modeling approach to the study of the linear friction welding of 30CrNiMo8 high strength steel Hero chain [13].…”

“…The numerical modeling approach to the study of the linear friction welding of 30CrNiMo8 high strength steel Hero chain [13].…”