A Novel Process Modeling Framework for Linear Friction Welding

Linear friction welding (LFW) is a solid state joining process that is increasing attracting attention in aerospace industry, due its several advantages like absence of solidification defects, no requirement for external heat source, and mechanical and fatigue properties of the weld being equivalent or surpassing the parent material. The complexity of LFW process necessitates the need for development of process modeling and simulation tools which enable investigation of the influence of LFW process parameters on weld characteristics. Commercially available software are limited to modeling of linear friction welding in 2D using Finite Element Method with adaptive mesh controls, such as Arbitrary Lagrangian Eulerian. Under this Phase II SBIR, ACT proposes to continue the development of its novel meshless particle method for efficient modeling of LFW process in 3D. The effort builds on the successful proof-of-concept results from Phase I. The Phase II effort will mature the model framework to account for interface bonding, flash formation, and joint of dissimilar materials. Further, it will include verification and validation of modeling framework to yield a predictive modeling tool that is capable of guiding LFW processes in industrial applications.