Optimization of heat transfer in the finite element process modelling of inertia friction welding of SCMV and AerMet 100

Abstract

Inertia friction welding is the process in which stored kinetic energy in a flywheel is converted to heat by relative sliding movement between the components' surfaces. The process is widely used in joining high strength aero-engine alloys. Heat transfer interactions play a fundamental role in determining weld quality as temperature has a significant impact on the mechanical, thermal and metallurgical behaviours of materials. Heating and cooling rates influence thermal stresses induced by variations in material properties due to variations in temperatures. Heat transfer modes involved in the IFW process, apart from conduction, were hardly mentioned in previous work while their significance has not been identified. In this paper the heat transfer modes and their significance in the modelling of the IFW process of the high strength steels SCMV and AerMet 100 has been identified and a methodology by which experimental, numerical and empirical approaches were collectively utilised to optimize the heat transfer analysis is presented. The methodology was validated for optimizing the heat transfer analysis of the IFW process of the high strength steels that are the subject of this study.

Modelling of Inertia Friction Welding Using Finite Element Analysis and Computational Fluid Dynamics

“…Material Forming ESAFORM 2014 (coulomb friction) was specified at the interface between the components as a function of process time as specified by Bennett et al [8]. The value for the interface heat transfer coefficient was specified as 1×10 4 N/s/mm/K following the study of Mohammed et al [16] . The initial rotation velocity of 122.5 rad/s was defined using energy based method giving the die an initial energy of 2.3286×10 8 Nmm with a moment of inertia 30973 Nmms 2 .…”

Finite Element Modelling and Optimization of Rotary Friction Welding Parameters of High-Density Polyethylene Pipes (HDPE). (c2022)

“…During the initial heating stage, the authors showed that frictional shear stress depends on the interaction of surface asperities and is affected by the axial pressure and flow stress of the material. Mohammed et al (2010) performed a simulation of IFW of SCMV to AerMet-100 with the aim of investigating the importance of heat transfer modes during the process.…”

“…Yang, 2010). Mohammed et al (2010) concluded that conduction dominates the other heat transfer mechanisms during the welding stage, and that considering convection and radiation has little influence because the temperature gradient in the pipes surpasses that between the pipes and the environment. Conduction also remains the controlling heat transfer mode during the primary stage of cooling.…”