Numerical simulation of rotary friction welding of Ti-6Al-4V tubes

A two-dimensional model of continuous drive friction welding (CDFW) of Ti-6Al-4V tubes was developed using the ABAQUS modeling software. The effect of interface temperature on frictional behavior during welding was investigated, where non-linear temperature-dependent material properties were considered. The effects of rotational speed and friction pressure on the temperature field, flash morphology, interface temperature, and axial shortening of the joints were studied. Results show that the interface temperature rises rapidly early in the process, to reach a plateau at 1270 °C. For a constant welding time, the temperature gradients and axial shortening of the joints increase with increasing the rotating speed and friction pressure; the steady-state temperature of the interface increases with the increase of rotational speed and decreases with the increase of axial pressure; following welding, the expelled material in the form of a flash curls on the outer wall of the tube, while being symmetrical about the welding interface. Modeling results were well validated with CDFW experiments.