Efficient 3-D Finite Element Process Modeling to Enable Linear Friction Welding of Aerospace Components

Solid state joining process such as linear friction welding (LFW) is being increasingly used in the aerospace industry for welding similar and dissimilar materials. Existing LFW modeling tools doesn’t adequately address the challenges highlighted above and currently it is a challenge to complete a simulation of complete LFW process and even the incomplete modeling of LFW process takes a very long time, rendering the current modeling methods impractical for industrial use. The overall technical objectives for this project is to develop, implement and demonstrate a fully validated, computationally efficient methodology to model LFW model in DEFORM 3D system. At the end of Phase II part of the project, it is expected that that DEFORM 3D LFW models would be able to reasonably predict temperature profiles, upset rates, flash shapes that are validated with experimental results of LFW of IN718 coupons. The primary focus of this effort is to achieve considerable speed up in modeling LFW process.