On the Solid Bonding Phenomena in Linear Friction Welding and Accumulative Roll Bonding Processes: Numerical Simulation Insights

Solid Bonding based welding processes allow to obtain defect free joints with lowresidual stress and low distortion. However, the engineering and optimization of solid bondingprocesses is difficult and requires a large number of time and cost consuming test trials. In this way,proper numerical models are essential tools permitting effective process design.The aim of this research was the comparison of the material process conditions during twodifferent manufacturing processes taking advantage of the same metallurgical phenomenon, namelysolid bonding. Linear Friction Welding, used to weld non-axisymmetric components andAccumulative Roll Bonding, used to increase the mechanical properties of sheet metals, wereconsidered. Numerical models were set up, validated and used to design the process by studying thecomplex material behavior during the solid bonding of different aluminum alloys.An implicit approach was used for the Linear Friction Welding and Accumulative Roll Bondingprocesses, leading to the understanding of the main process variables influence on the fieldvariables distribution and the occurrence of actual bonding