Numerical Simulation Of Inertia Friction Welding Process Of GH4169 Alloy Large-sized Ring

As being one of the most advanced solid phase welding technologies, inertia friction welding (IFW) has been widely used in modern aeronautic industry. The aeroengine components are high precision workpieces and complicated in shape. Therefore, it is important to research on the factors of IFW process for the optimization design and joint quality control.By the traditional "trail and error" method, the cost of designing a set of friction welding parameters for the large-sized critical component of aeroengine is too high. While adopting the numerical simulation method, the lead time and cost will be reduced significantly.In present dissertation, an axisymmetric elastic-plastic model of GH4169 alloy large-sized ring during IFW process was established by using the finite element (FE) software MSC.Marc. Half of the axial section was selected as simulation area. The mesh near friction interface was subdivided and defined as deformable bodies separately. The model was used to study the symmetry of the temperature and stress field. The temperature field was significantly symmetric about the friction interface, While the equivalent stress field had few symmetry about it.The axial shortening was one of the critical factors of joint quality control. The effects of the ring radius, thickness, rotation speed and friction force on the axial shortening were simulated. For a given ring thickness and welding parameters, the axial shortening increased with the ring radius and then decreased with it. As the ring radius and welding parameters were given, the axial shortening decreased rapidly with the ring thickness until it was higher than a critical value. The axial shortening was sensitive to the rotation speed and increased rapidly with it. The friction force has little influence on the axial shortening. These effects on the axial shortening were similar to them on the depth of 800℃ heat affected zone (HAZ).To verify the FE models, the calculated data of transient temperature field and axial shortening were compared to the measured ones. They were shown in good agreement respectively. The FE models were valid and the calculated results were reliable.