Investigations on the linear friction welding process through numerical simulations and experiments

Linear Friction Welding (LFW) is a solid-state joining process applied to non-axisymmetric components. LFW involves joining of materials through the relative motion of two components undergoing an axial force. In such process the heat source is given by the frictional forces work decaying into heat determining a local softening of the material and eventually bonding conditions. In the paper the authors present a designed and assembled laboratory fixture for LFW operations and the results of an experimental and numerical campaign aimed to weld steel parts. The dedicated fixture permitted to highlight the effect of the most important process parameters. Process conditions allowing effective bonding conditions were highlighted and local conditions of pressure and temperature determining effective bonding of the specimens were determined.

► A new fixture for LFW operation was designed, assembled and tested. ► A FEM model of the process was set up and tuned on the basis of experimental tests. ► The influence of relevant process parameters on the bonding conditions was studied.