Abstract

A new model of the material flow in rotary friction welding of tubes is proposed. The material flow proposed is based on 3D scans of welds performed with tungsten tracers. The tracers indicate a bifurcation of flow into two deformation paths. A different analysis is performed on each path.The material in Path 1 interacts with the weld interface and exhibits large amounts of azimuthal flow. Previous analytical investigations that have analytically modelled the weld interface as a non-Newtonian fluid are used to calculate the strain rate in this zone.The material in Path 2 transitions from axial to primarily radial flow. The assumption of no azimuthal flow in Path 2 is validated through experimental results of the tracer study. The directional transition in this path is compared to orthogonal machining and equal channel angular pressing. The process to estimate the variables needed to calculate strain and strain rates using the equations from orthogonal machining and equal channel angular pressing is defined. Strain and strain rate in Path 2 are dependent upon feedrate and upset. Both decrease throughout the welding process. The strain rate is higher than previous studies in rotary friction welding because of the deformation model proposed.

Degree

College and Department

Ira A. Fulton College of Engineering and Technology; Mechanical Engineering

Rights

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