Finite element modelling of the inertia friction welding process between dissimilar materials

The present study concerns the development and experimental validation of a finite element code to simulate the inertia friction welding (IFW) process. The mechanical equations take into account, among others, the physics in terms of inertia, forces and friction. They are solved for velocity and pressure through the P1+/P1 formulation. Due to the rotational movement of the workpiece, a third nodal unknown Vθ, the rotational velocity, is added to the variables Vr and Vz. The thermal calculation influences the rheological and tribological parameters and is coupled to the mechanical solution. Powerful contact algorithm and automatic remeshing are implemented to model the flash formation at the joint interface, its self-contact with the workpiece and the multi-body contact between dissimilar materials. A novel formulation for the friction law is implemented to suitably represent the physical phenomena in IFW. A residual stress analysis is carried out.