Modelling of the flow stress behaviour for rotary friction welding

Espadero Sanchez-Crespo, Miguel (2025). Modelling of the flow stress behaviour for rotary friction welding. University of Birmingham. Ph.D.

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Abstract

The aim of this work is the development of a physics-based constitutive framework for modelling the evolution of the thermo-mechanical and microstructural fields during inertia friction welding of precipitate strengthened nickel-based superalloys. This framework seeks to provide deeper insights into the process, contributing to improving weld integrity.

As a joining method, rotary friction welding is a widely used joining process because it has many benefits such as being a solid-state process, generates localised heat zones, extrusion of material cleans the weld, and the process is cost effective. However, it is not easy to model since during the process the material is exposed to elevated temperatures and large strain rates that lead to major changes in the microstructure.

In this work, one key objective is to investigate dominant micromechanisms believed to control the flow stress during the welding process. It also develops a finite element scheme that couples mean field predictions to the physics-based flow stress model within the commercial finite element software ABAQUS.

The framework developed in this work can assess the weld integrity by analysing the variables provided by the model, contributing to efficient process development with reduced lead-time, cost and material.

Type of Work:

Thesis (Doctorates > Ph.D.)

Award Type:

Doctorates > Ph.D.

Supervisor(s):