Geometric effects of friction welding on residual stress

Friction welding (FW) is a promising solid-state joining technology. Except joining purpose, it has been widely used for the repair of damaged components or manufacturing of preforms of complex components. As other welding processes, strong local heat input leads to the formation of high tensile residual stress (RS) during FW. Numerical prediction of RS is critical for the assessment of structure integrity of FW. Compared to traditional welding, FW includes a lot of variables that have profound influence on RS distribution. For instance, presented research showed that applied pressure has significant effect on RS. However, the geometric effects of components on residual stresses has not been investigated yet. One of key advantages of FW is to provide the possibility to manufacture preforms of complex parts with less raw material, thus, the welding interface with various cross sections are inevitable. Based on validated finite element model, we try to further investigated the geometric effects on RS and build the relationship between geometric effects and RS distribution. It deepens the understanding of RS evolution patterns of FW and potential optimizing directions.