Process optimization of rotary friction welding of Ti-6Al-4V alloy rods

Abstract: This paper presents an investigation on the performance of rotary friction welded 25.4 mm diameter Ti-6Al-4V alloy rods. The process parameters used are friction and forging pressure, rotational speed, forging time and upset distance. The heating time was determined by the amount of friction pressure and rotational speed utilised. The final weld joints were examined for mechanical properties. The results revealed that friction welding process parameters have significant influence on the weld joint properties and weld joint integrity. The hardness and ultimate tensile properties of the weld joints varied with the variation in rotational speed and axial pressure. The tensile properties of the weld joints were higher than the parent material at lower rotational speed or higher axial pressure. The weld width was proportional to relative motion and inversely proportional to axial pressure