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Efficient 3-D Finite Element Process Modeling to Enable Linear Friction Welding of Aerospace Components



OBJECTIVE: The objective of this SBIR is to develop fully-validated cost and time efficient methods to model (in 3-dimensions) the linear friction welding process of Ni-base superalloys or titanium alloys. 

DESCRIPTION: In an effort to reduce to industrial practice the utilization of 3-D finite element process modeling of linear friction welding, significant challenges relating to the time and expertise required to run the model must be mitigated. 3-D finite element process modeling is a main challenge limiting increased utilization of linear friction welding in military engine hardware designs. Limited information has been reported in the open literature regarding the utilization of 3-D finite element modeling of the linear friction welding process. Further, the time required to model the process in three dimensions is not reasonable in an industrial application environment. Two dimensional modeling does not allow for full and accurate accounting of deformation in all directions at the weld line. 

PHASE I: Process modeling exploration to include software selection, and methodology to reduce computational time required for fully-validated 3-D process modeling of linear friction welding. Planning for modeling and experimental validation to take place in phase II. It is expected that a design of experiments or other suitable approach will be utilized for the experimental weld validation. Benchmarking the state of the art capability in process modeling for linear friction welding will be completed. This will include both simulation time required, as well as accuracy of model predictions (temperature profiles, upset rates, flash formation etc). 

PHASE II: Fully develop, demonstrate and validate 3-D process modeling capability for linear friction welding of either Ni-base superalloys or titanium alloys (dissimilar couples) relevant to military or commercial engine hardware. Demonstrate a reduction in computation time and complexity for the process modeling capability over the current state of the art. 

PHASE III: Further development and implementation of the 3-D modeling capability with a military or commercial aerospace OEM supplier on a relevant component geometry. Extend and validate the model for another alloy class (Ni-base superalloy or titanium). 


1: Li, Vairis, Preuss, Ma. (2016) Linear and Rotary Friction Welding Review. International Materials Reviews. Vol 61 No 2, 71-100.

2:  Maalekian. (2007) Friction welding - critical assessment of literature. Science and Technology of Welding and Joining. Vol 12 No 8, 708-729.

3:  Chamanfar, Jahazi, and Cormier. (2015) A Review on Inertia and Linear Friction Welding of Ni-Based Superalloys. Metallurgical and materials Transactions A. 46: 1639.

KEYWORDS: 3D Finite Element Modeling, Linear Friction Welding, Computational Efficiency 


David Mahaffey (LPAE) 

(937) 255-3233 

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