Manufacturing modification through process manipulation in inertia friction welding: enhanced functionality rotary friction welding

Ashwell, Richard Christopher (2021). Manufacturing modification through process manipulation in inertia friction welding: enhanced functionality rotary friction welding. University of Birmingham. Eng.D.

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Abstract

Rotary friction welding has been around since the end of the Second World War. Until recently machines and the process have only improved with the introduction of easier control systems and more accurate instrumentation. Recently, however, Manufacturing Technology Inc developed a range of enhanced functionalities based on combining the two fundamental processing options: Inertia and Continuous drive. The aim of this thesis is to explore the new enhanced functionalities and gain an understanding of their influence on the weld to examine potential process improvements.
Initially all the various forms of enhanced functionality are reviewed in order to assess the potential for further use. Torque modulation, where the rotational speed can be modified mid cycle in reference to a profile, was found to have the greatest impact on the standard cycle, substantially reducing the variation in upset, with no noticeable impact on the weld microstructure. Final length control demonstrated an impact on the microstructure away from the nominal if large energy inputs were utilized. Simulated inertia profiles used large energy inputs to purposefully modify the process and resulting microstructure. Links were found between the process, corresponding weld zone widths and resultant residual stresses in Titanium 6Al 4V.

Type of Work: Thesis (Doctorates > Eng.D.)
Award Type: Doctorates > Eng.D.
Supervisor(s):
Supervisor(s)EmailORCID
Attallah, MoatazUNSPECIFIEDUNSPECIFIED
Bowen, PaulUNSPECIFIEDUNSPECIFIED
Licence: All rights reserved
College/Faculty: Colleges (2008 onwards) > College of Engineering & Physical Sciences
School or Department: School of Metallurgy and Materials
Funders: Engineering and Physical Sciences Research Council
Subjects: T Technology > TJ Mechanical engineering and machinery
T Technology > TS Manufactures
URI: http://etheses.bham.ac.uk/id/eprint/11451

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