Research of Flash Forming During Inertia Friction Welding of FGH96 Alloy

On basis of the constitutive equation of FGH96 alloy and the relation between friction coefficient and temperature, the coupled thermo-mechanical model of inertia friction welding of FGH96 alloy is established using DEFORM software. The relation between the flash forming and material flow is investigated. The results show that the flash doesn't appear in the early stage of welding because the temperature and the velocity of material flow are both small. After the welding process reaches stable state, the material near two edges of friction edge flows towards the outside of friction surface, which results in the appearance of flash and the dimensions of flash increase with the continuance of welding time. With the increase of the initial velocity or the axial press, both the dimension and the bending extent of the flash are increased. Moreover, the method to determine the reasonable welding parameters is put forward based on the appearance of the flash.