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19-09-2015, 04:01 PM

what are the steps to analysis the friction welding in ansys

jaseela123d · 10-03-2017, 10:53 AM

Friction welding (FRW) is a solid-state welding process that generates heat through mechanical friction between workpieces in relative motion with each other, with the addition of a lateral force called "disruption" to plastically move and melt the materials. Because no melting occurs, friction welding is not a fusion welding process in the traditional sense, but rather a forging welding technique. Friction welding is used with metals and thermoplastics in a wide variety of aviation and automotive applications.

The combination of fast bonding times (on the order of a few seconds) and direct heat input at the weld interface produces relatively small areas affected by heat. Friction welding techniques are generally non-melt, which mitigates grain growth in engineering materials, such as thermally treated high strength steels. Another advantage is that the movement tends to "clean" the surface between the materials being welded, which means that they can be bonded with less preparation. During the welding process, depending on the method used, small pieces of plastic or metal will be forced out of the working mass (flash). It is believed that the flash carries the debris and dirt.

Another advantage of friction welding is that it allows to join different materials. This is particularly useful in the aerospace sector, where it is used to attach lightweight aluminum material to high strength steels. Normally, the great difference in the melting points of the two materials would make it impossible to weld using traditional techniques and would require some kind of mechanical connection. Friction welding provides a "full strength" bond without additional weight. Other common uses for this type of bimetallic gaskets are found in the nuclear industry, where copper and steel gaskets are common in reactor cooling systems; And in the transport of cryogenic fluids, where friction welding has been used to join aluminum alloys to stainless steels and high nickel alloy materials for cryogenic fluid pipes and containment vessels.

Friction welding is also used with thermoplastics, which act in a manner analogous to metals under heat and pressure. The heat and pressure used in these materials are much lower than metals, but the technique can be used to attach metals to plastics with the metal interface being machined. For example, the technique can be used to attach glasses frames to the pins on their hinges. The lower energies and pressures used allow a greater variety of techniques to be used.

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