Projects per year
Abstract
Inertia friction welding (IFW), a type of rotary friction welding process, is widely used across aerospace, automotive and powergeneration industries. The process considers a specialist rotary friction welding machine, which asks for the critical process parameters of inertial mass, initial rotational speed and applied pressure, to complete the relevant weld. The total kinetic energy available to the system can be calculated from basic physical relationships for the kinetic energy stored in a flywheel. This kinetic energy must be converted partly to heating the specimen at the interface, and partly to mechanical work via deformations. A finite element (FE) numerical model has been developed to predict the steadystate thermal profiles formed at the onset of mechanical deformation. Therefore, the amount of this total available energy for the process which is applied to the heating of the component at the interface through frictional contact has been estimated. Thus, the available energy left to produce the mechanical deformation via the flash formation can be calculated by subtracting the thermal energy from the total energy. This is of importance to the manufacturing engineer. A method of validating the FE modelling predictions was proposed using highspeed photography methods during the process to understand the rotational speed of the moving part at the instant that the steadystate deformation commences. Results from FE modelling and experiment suggest that the width of the steadystate thermal profile formed through the IFW, and the time taken to reach steadystate is strongly dependent upon the applied pressure parameter.
Original language  English 

Pages (fromto)  186–194 
Journal  Journal of Manufacturing Processes 
Volume  24 
Issue number  1 
Early online date  30 Sep 2016 
DOIs  
Publication status  Published  Oct 2016 
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Dive into the research topics of 'Calculating the energy required to undergo the conditioning phase of a titanium alloy inertia friction weld'. Together they form a unique fingerprint.Projects
 1 Finished

Structural Metallic Systems For Advanced Gas Turbine Applications
Bowen, P., Chiu, Y. & Reed, R.
Engineering & Physical Science Research Council
1/10/09 → 30/09/14
Project: Research Councils
Equipment

Birmingham Environment for Academic Research (BEAR)
Facility/equipment: Equipment