Experimental investigation of rotational friction welding for EN AW-6082 – 20MnCr5 joints
Ahmed Dewidar, Alexej Verschinin, Norman Mohnfeld, Hendrik Wester, Sebastian Barton, Hans Jürgen Maier, Johanna Uhe
Abstract. Rotary Friction welding is utilised in various industries, particularly for joining dissimilar materials in mass production, due to its advantages such as minimal material waste, low energy consumption, excellent static and dynamic bond strengths and short production times. This study investigates the effects of process parameters, including friction pressure (80 – 119.4 MPa), friction path (5 – 8 mm), forging pressure (175 – 225 MPa) and forging time (5 – 10 s), on the properties of friction-welded joints between EN AW-6082 and 20MnCr5. Experiments were conducted on cylindrical specimens (Ø 40 mm × 100 mm) using a KUKA Genius Plus RS30. Bond strength was measured using local and global tensile tests. In addition, eddy current testing was employed to investigate its potential in the assessment and prediction of the weld quality of dissimilar RFW joints. The results, analysed using analysis of variance (ANOVA), revealed that higher forging pressures significantly improved bond strength. Moreover, higher values of friction pressure slightly improved bond strength, whereas higher values of friction path negatively influenced it, compared to the respective lower values of the same parameter combination. However, their individual effects were less pronounced compared to forging pressure.
Keywords
Rotary Friction Welding, Bond Strength, Non-Destructive Testing
Published online 5/7/2025, 10 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Ahmed Dewidar, Alexej Verschinin, Norman Mohnfeld, Hendrik Wester, Sebastian Barton, Hans Jürgen Maier, Johanna Uhe, Experimental investigation of rotational friction welding for EN AW-6082 – 20MnCr5 joints, Materials Research Proceedings, Vol. 54, pp 1479-1488, 2025
DOI: https://doi.org/10.21741/9781644903599-160
The article was published as article 160 of the book Material Forming
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
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