Numerical investigation of friction crush welding aluminium and copper sheet metals with flanged edges

Abstract

Aluminum alloys are the most attractive solutions for many industries including aerospace, marine, and other transportation sectors where lightweight construction is required. Friction Crush Welding (FCW) is a new material joining process that simultaneously creates a mechanical lock and a metallurgical seal at the interface between similar and dissimilar materials. In this research work presents the development of numerical modelling to predict the temperature distribution and mechanical performance of aluminum and copper similar joints in the FCW of sheet metal section. An explicit nonlinear transient finite element thermomechanical model is develop using ABAQUS based on the coupled Euler-Lagrange method to simulate FCW of AW5754 and Cu-DHP alloys. The Johnson-Cook materials law is adopted in the FEM. Numerical investigations of the FCW process was performed to reduce experimental testing times, which can be long and expensive. Temperature distribution and von misses stress flow patterns are observed at the top surface of the weld. Numerical simulation data correlate with experimental data in the literature.

Friction Crush Welding of Dissimilar Materials: Numerical Modelling and Experimental Investigation

“…Welding speed has maximum influence on the strength of the connection created by the FCW process [24]. Kumar and Brar (2021) developed a numerical model to forecast the temperature pattern and mechanical behaviour of identical joints made of Aluminium and Copper in an FCW of sheet metal sections [25]. Singh et al (2023) examined the FCW between dissimilar junctions made of Aluminium 6061-T6 and Stainless Steel 304 using feed speed of 15, 30, and 45 mm/min and tool revolutions of 2000, 3000, and 4000 rpm.…”