Numerical investigation of rotational friction welding for C22.8 - 41Cr4 joints using a substitute model

Abstract

Abstract. Rotational friction welding (RFW) is a solid-state joining process that enables the joining of similar and dissimilar materials such as metal-metal or metal-ceramic joints. Due to its high application flexibility, this process has great potential for the production of hybrid components. In order to be able to realise this potential for the production of hybrid components, the development of an improved process design is required. Due to the complexity of the process, the Finite Element Method (FEM) can be used to solve complex problems and is therefore an established tool for the design of joining processes. This work focuses on the development of an FE model to represent the RFW process of C22.8 and 41Cr4 joints. The material data required for the numerical representation of the RFW were obtained from isothermal cylinder compression tests. The frictional heat which is generated during RFW is calculated using a substitute model, which mainly depends on the Y-factor. The Y-factor indicates what percentage of the calculated frictional energy is introduced into the process. The Y-factor was determined and then verified using experimental data. A general validity of the determined Y-factors with changed process parameters could not be achieved.