Finite Element Modeling of Continuous Drive Friction Welding of Al/GNP’s: Thermal and Mechanical Properties

Solid-state friction welding (SSFW) stands out as a frequently utilized assembly method, employing diffusion at temperatures below material melting points. This approach effectively mitigates melting and solidification issues in contrast to fusion welding methods. Enhancing thermal and mechanical properties of welded parts through reinforcing agents shows promise. The current work involvies continuous drive friction welding (CDFW) of graphene nano platellets infused in AA6061; a coupled heat transfer and mechanical deformation were considered. The findings revealed that incorporating graphene into AA6061 improved heat distribution, modifying the heat-affected zone behavior and reducing the maximum temperature at the welded interface by 13%. However, a 5% reduction in ultimate tensile strength (UTS) compared to the base material was observed in welded AA6061 parts. Nevertheless, adding graphene at the welding interface improved UTS by 3.5%, enhancing overall operational efficiency, reducing costs, time, and environmental impact. The modeling of coupled thermo-mechanical phenomena successfully reproduced experimental results, highlighting the potential of computing power and finite element analysis for cost-effective outcomes and paving the way for further investigations.