Finite element process modelling of inertia friction welding advanced nickel-based superalloy
Finite element process modelling of inertia friction welding advanced nickel-based superalloy
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DOI：
10.1016/j.msea.2009.02.005
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发表时间：
2009-07
期刊：
影响因子：
6.4
通讯作者：
B. Grant;M. Preuss;P. Withers;G. Baxter;M. Rowlson
中科院分区：
文献类型：
--
作者：
B. Grant;M. Preuss;P. Withers;G. Baxter;M. Rowlson
使用 DEFORM 8.2 软件包开发了顺序耦合的热和机械有限元 (FE) 模型来描述惯性摩擦焊接 (IFW)。所有建模和实验工作均针对 RR1000 制成的惯性摩擦焊缝进行，RR1000 是一种先进的高 γ' 含量镍基高温合金。热预测的准确性通过分析整个焊接区域的 γ' 分布（与规定热模拟期间记录的分布进行比较）进行了评估，同时通过比较预测和测量的加厚和焊接压力来验证机械模型。最后，将残余应力预测与测量结果进行了比较（通过中子衍射）。在所有情况下，预测数据和实验数据之间都存在极好的一致性。这项练习表明，焊接过程中施加的夹紧力可能对轴向应力场有很大的影响。然后使用经过验证的模型来研究焊接压力对材料流动、热历史和残余应力的影响。研究表明，随着焊接压力的增加，热影响区 (HAZ) 的宽度会减小，而峰值温度和应变速率会增加。此外，发现焊缝附近环向的峰值应力很大程度上不受焊接压力的影响。然而，对于较低的焊接压力，随着热影响区的增加，发现了更宽的高拉伸环向应力区域。
A sequentially coupled thermal and mechanical finite element (FE) model has been developed to describe inertia friction welding (IFW) using the DEFORM 8.2 package. All modelling and experimental work was undertaken on inertia friction welds made from RR1000, which is an advanced high γ′ content nickel-based superalloy. The accuracy of the thermal predictions has been assessed by an analysis of γ′ distribution across the weld region as compared to those recorded during prescribed thermal simulations, while the mechanical model has been validated by comparing predicted and measured upsets and weld pressures. Finally the residual stress predictions have been compared against measurements (by neutron diffraction). In all cases excellent agreement was found between predicted and experimental data. This exercise revealed that the clamping forces applied during the welding process may have a strong influence on the axial stress field. The validated model was then used to study the effect of welding pressure on material flow, thermal history and residual stresses. The work shows that with increasing weld pressure the width of the heat-affected zone (HAZ) is reduced, while the peak temperature and strain rate is increased. In addition the peak stresses in the hoop direction near the weldline were found to be largely unaffected by the weld pressure. However, for lower welding pressures a broader high tensile hoop stress region was found in accordance with the increased HAZ.