Design of high performace rotary friction tooling systems for the manufacture of aero-engine components

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The need for high-quality joints, combined with the inherent difficulty in welding most aerospace materials, has fostered aerospace industry to research in solid-state friction-based welding processes. Rotary friction welding, in particular, is a solid state friction welding technique that allows to weld together cylindrical parts by means of the heat generated due to the friction at the interface between the two components and the forging pressure applied by a ram.The aim of the PhD is to develop a novel specialist tool able to solve issues in the fixturing system in order to improve the weld quality. In order to do that, it is fundamental to implement a numerical model able to describe accurately the process and a measurement system able to extract strategic experimental data for cross-comparison.