Plastic flow and interfacial bonding behaviors of embedded linear friction welding process:Numerical simulation combined with thermophysical experiment  

作　　者：Tiejun MA Zhenguo GUO Xiawei YANG Junlong JIN Xi CHEN Jun TAO Wenya LI Achilles VAIRIS Liukuan YU 

机构地区：[1]State Key Laboratory of Solidification Processing,Shaanxi Key Laboratory of Friction Welding Technologies,Northwestern Polytechnical University,Xi'an 710072,China [2]Aeronautical Key Laboratory for Welding and Joining Technologies,AVIC Manufacturing Technology Institute,Beijing 100024,China [3]Mechanical Engineering Department,University of West Attica,Athens 12241,Greece [4]Mathematic and Physic Department,Xianjiaotong-liverpool University,Suzhou 215123,China

出　　处：《Chinese Journal of Aeronautics》2025年第1期87-98,共12页中国航空学报(英文版)

基　　金：co-supported by the National Natural Science Foundation of China(Nos.52105411,52105400and 52305420);the China Postdoctoral Science Foundation(No.2023M742830);Innovation Foundation for Doctor Dissertation of Northwestern Polytechnical University(No.CX2023008).

摘　　要：In this study,a new linear friction welding(LFW)process,embedded LFW process,was put forward,which was mainly applied to combination manufacturing of long or overlong loadcarrying titanium alloy structural components in aircraft.The interfacial plastic flow behavior and bonding mechanism of this process were investigated by a developed coupling EulerianLagrangian numerical model using software ABAQUS and a novel thermo-physical simulation method with designed embedded hot compression specimen.In addition,the formation mechanism and control method of welding defects caused by uneven plastic flow were discussed.The results reveal that the plastic flow along oscillating direction of this process is even and sufficient.In the direction perpendicular to oscillation,thermo-plastic metals mainly flow downward along welding interface under coupling of shear stress and interfacial pressure,resulting in the interfacial plastic zone shown as an inverted“V”shape.The upward plastic flow in this direction is relatively weak,and only a small amount of flash is extruded from top of joint.Moreover,the wedge block and welding components at top of joint are always in un-steady friction stage,leading to nonuniform temperature field distribution and un-welded defects.According to the results of numerical simulation,high oscillating frequency combined with low pressure and small amplitude is considered as appropriate parameter selection scheme to improve the upward interfacial plastic flow at top of joint and suppress the un-welded defects.The results of thermo-physical simulation illustrate that continuous dynamic recrystallization(CDRX)induces the bonding of interface,accompanying by intense dislocation movement and creation of many low-angle grain boundaries.In the interfacial bonding area,grain orientation is random with relatively low texture density(5.0 mud)owing to CDRX.

关 键 词：Embedded linear friction welding Plastic flow Interfacial bonding behavior Numerical simulation Thermo-physical simulation Temperature field Dynamic recrystallization 

分 类 号：TG453.9[金属学及工艺—焊接] V261.34[航空宇航科学与技术—航空宇航制造工程]