Elucidating the in-process interfacial friction regime and thermal responses during inertia friction welding of dissimilar superalloys

Inertia friction welding (IFW) is a robust joining technique, particularly for hybrid structures composed of similar or dissimilar alloys. The highly transient thermal responses during friction heating produce variations in heat generation and temperature distribution, which are crucial for designing and controlling the IFW process. This study establishes a finite element (FE) model of the IFW process for dissimilar superalloys and investigates the transition of the interfacial friction regime and its impact on the transient thermal responses. The in-process state variables, including the frictional stress and heat flux, along with their spatial distributions at the welding interface, are obtained through FE simulations. The predicted results indicate that the transient transition of the friction regime produces 2 C friction zones accompanied by a shear friction zone. To capture the transient evolution of the friction regime, a novel phenomenological formula is developed. This model accurately predicts the shrinkage and disappearance of the 2 C friction zones and the enhancement of the shear friction zone from the initial 0.42 R0–0.87 R0 (where R0 is the workpiece radius) to the entire interface during the IFW process. The variations in interfacial heat flux, frictional stress, and temperature caused by the transition of the friction regime are comprehensively analyzed. Our results reveal that the transition from the Coulomb friction regime to shear friction regime at the interface is beneficial for temperature homogenization at the welding interface. The FE simulation results are validated against published experimental measurements, which confirms the accuracy and reliability of the FE model.