Material flow during friction hydro-pillar processing

Abstract

Friction hydro-pillar processing (FHPP) is a novel technique that involves solid-state joining of an external plug onto a substrate by plastic deformation. A systematic investigation on material flow during FHPP is required but rarely reported. The present work reports a coupled theoretical and a three-dimensional X-ray computer tomography-based experimental study using a Ti-alloy as a tracer material to realise the material flow during FHPP of a AISI 4140 steel substrate. The cumulative results showed that the central portion of the plug deformed in a series of layer-wise shear planes. However, the plasticised material towards the outer area of the plug flowed through the clearance between the plug and the substrate with excess volume moving out as flash.

KEYWORDS:

• Friction welding
• friction hydro-pillar processing
• friction taper plug welding
• material flow
• X-ray computer tomography
• numerical simulation
• AISI 4140 steel
• Ti–6Al–4V

Acknowledgements

The authors would like to thank the research support of Petrobras, ANP (Brazilian Agency for Petroleum and Energy) and General Electric. The authors are thankful to the late Professor T.R. Strohaecker (LAMEF/PPGE3M), whose presence and wisdom will be profoundly missed.

Disclosure statement

No potential conflict of interest was reported by the authors.

ORCID

Buchibabu Vicharapu http://orcid.org/0000-0003-2091-8022

Amitava De http://orcid.org/0000-0002-3109-261X