Thermo-Mechanical Finite Element Simulation and Experimental Investigation of Rotary Friction Welding of Dissimilar Materials

Abstract

This study investigates the thermo-mechanical behavior of AISI 4140 steel and Inconel 718 during direct-drive rotary friction welding using finite element analysis and experimental approaches. The welding was modeled under rotational motion of the Inconel 718 specimen combined with axial compressive loading applied to the AISI 4140 specimen. The numerical analysis focused on the stress distribution during the forging stage, during which severe plastic deformation and interfacial bonding occur. The simulation results indicate that the stress state is not purely compressive but rather a coupled compression-shear condition arising from the combined effects of axial force and rotational friction. The von Mises stress distribution revealed a localized stress concentration near the welding interface, indicating significant plastic flow and material interaction. Furthermore, the dissimilar mechanical properties of AISI 4140 and Inconel 718 influenced the stress localization behavior and deformation characteristics during welding. The findings provide useful insights into the deformation mechanism and stress evolution in rotary friction welding of dissimilar materials and may help optimize welding parameters and joint quality.