A New Method of Predicting the Parameters of the Rotational Friction Welding Process Based on the Determination of the Frictional Heat Transfer in Ti Grade 2/AA 5005 Joints

The article presents an original approach to determining the basic parameters of rotational friction welding (RFW) based on the analysis of friction heat transfer at the faying surfaces. Dissimilar Ti Grade 2/AA 5005 joints were used to demonstrate the method. The work established that for the analyzed joint, the optimum temperature at the faying surface that allow for a good quality weld to be obtained should be ~505 °C. On this basis, a map of optimal parameters was developed to achieve this temperature. This approach could potentially allow for more precise control of the welding process, leading to better joint quality and performance. The paper includes both a description of the technological process of friction welding and an attempt to explain the mechanism of the phenomena occurring in the welding area. The numerical calculations presented in the article were carried out using the ADINA System v. 9.8.2, which allows for the consideration of heat friction in the axial symmetric thermo-mechanical model. Frictional resistance was determined by the temperature-dependent friction coefficient. The assumed thermo-mechanical model required the determination of elastic-plastic properties versus temperature for the analyzed materials. The simulations of the friction welding were carried out for the different welding parameters and time. The different variants of friction welding were modelled.