Dynamic Analysis of Rotating Continuous Drive Friction Welding Joints of Al alloy (6061AA)

A rotating Continuous Drive Friction Welding (CDFW) is a solidity welding process, where the required heat for welding is produced by friction induced by the relative movement between a motionless part and its rotary counterpart. In the situation of aluminum alloy, grain coarsening and impurities redistribution on grain boundaries are the main problems during fusion welding, which may be partially avoided via rotary friction welding.

The current research attempts to study the influences of time, rotational speed, and applied force on the dynamic analysis of rotating (CDFW) joints for aluminum alloy (6061AA). Numerical methods use finite element models with unified mechanical properties, which are incorporated into a welded joint structure and used to calculate Eigen-parameters quickly. Two techniques are used in the experimental analysis. The first one uses Frequency Response Function (FRF) applied with the impact hammering test, while the second one utilizes the magneto strictive pulse-echo delay line for the characterization of friction welded joints.

The assortment of numerical and experimental techniques makes it possible to find an effective tool for studying the dynamic performance of rotating CDFW joints for an aluminum rod. The proposed model was found to be capable of operating at high speeds while avoiding the resonance state utilizing the Finite Element Modeling (FEM) and the results from the experiments. The results showed that the change in applied force has the greatest influence on the dynamic performance of the continuous drive friction welding joints.