Understanding thermal-mechanical variations and resulting joint integrity of pressure-controlled linear friction welding of thin-steel sheets

Shotri, Rishabh; Miura, Takuya; Geng, Peihao; Morisada, Yoshiaki; Ushioda, Kohsaku; Fujii, Hidetoshi

doi:https://doi.org/10.1016/j.ijmachtools.2024.104235

Understanding thermal-mechanical variations and resulting joint integrity of pressure-controlled linear friction welding of thin-steel sheets

Shotri, Rishabh; Miura, Takuya; Geng, Peihao et al.

International Journal of Machine Tools and Manufacture, 2025, 204, 104235

Number of Access:527（2025-08-16 00:38 Counts）

Identifier to cite or link to this item: https://hdl.handle.net/11094/100215

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Title	Understanding thermal-mechanical variations and resulting joint integrity of pressure-controlled linear friction welding of thin-steel sheets
Creator	CreatorName Shotri, Rishabh
	NRID 1000060781466 1000060781466 ORCID 0000-0002-8991-5412 0000-0002-8991-5412 researchmap permalink miuratky miuratky Scopus Author ID 55162450300 55162450300 CreatorName Miura, Takuya
	NRID 1000040900064 1000040900064 CreatorName Geng, Peihao
	NRID 1000000416356 1000000416356 researchmap permalink morisada morisada CreatorName Morisada, Yoshiaki
	CreatorName Ushioda, Kohsaku
	NRID 1000000247230 1000000247230 ORCID 0000-0002-5023-3844 0000-0002-5023-3844 researchmap permalink read0051741 read0051741 Scopus Author ID 7403071460 7403071460 CreatorName Fujii, Hidetoshi
Subject	Finite element
	Forging
	Linear friction welding
	Microstructure
	Numerical modeling
	Plastic flow
	Pressure-controlled
	Steel
Description	Shotri R., Miura T., Geng P., et al. Understanding thermal-mechanical variations and resulting joint integrity of pressure-controlled linear friction welding of thin-steel sheets. International Journal of Machine Tools and Manufacture 204, 104235 (2025); https://doi.org/10.1016/j.ijmachtools.2024.104235.
Abstract	Linear friction welding is a solid-state joining technology that bonds materials via friction heating and plastic deformation. This process is being extensively researched for welding metallic sheets with different dimensions; however, it involves difficulties in joining thin cross-sections due to extensive misalignment and unsteady plastic extrusion of softened materials at interfaces. This study introduces novel efforts for joining thin cross-sections through pressure-controlled oscillations and displacements, facilitating localized plastic flow essential for high-strength solid-state bond formation. This method is rare, and the results reveal base metal fractures in tensile-tested welded joints of 2 mm thick S45C steel sheets. The interfacial yielding at specific temperatures is obtained by applying pressure corresponding to the temperature-dependent strength of the material. Accordingly, the welding is attempted using a hydraulic-based clamping system designed to accommodate large sheet lengths while allowing precise control of the interface pressure and temperature to facilitate controlled material plastic discharge. However, the requisite joint evolution tracking remains infeasible due to the intricate weld designs and is instead uncovered through novel numerical investigations. Modeling simultaneous oscillations and forging displacement while maintaining pressure depicted the kinetics of continual interfacial deformation. The transient fluctuations in plastic stress and temperature increments distinguish the stages of forging under different conditions. The computed temperature vs. plastic strain and the measured change in interfacial microstructures from martensite to dynamically recrystallized very fine ferrite with fragmented small cementite explain the lower temperature welding for an increase in applied pressure, enhancing the understanding of linear friction welding of thin steel sections for industrial applications.
Publisher	Elsevier Ltd
Source Title	International Journal of Machine Tools and Manufacture
Volume (Issue)	204
Page	104235
Date of Issued	2025-01-01
Language	English
Handle URL	https://hdl.handle.net/11094/100215
PISSN	08906955
Relation.isIdenticalTo	DOI (Publisher Version) https://doi.org/10.1016/j.ijmachtools.2024.104235
Access Rights	open access
CopyRight	This article is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.
oaire:version	Version of Record
Category	学術雑誌論文 Journal Article

Resource Type	journal article
Local Type	Journal Article
DCTERMS.bibliographicCitation	International Journal of Machine Tools and Manufacture. 2025, 204, p. 104235
DC.title	Understanding thermal-mechanical variations and resulting joint integrity of pressure-controlled linear friction welding of thin-steel sheets
DC.creator	Shotri, Rishabh
	Miura, Takuya
	Geng, Peihao
	Morisada, Yoshiaki
	Ushioda, Kohsaku
	Fujii, Hidetoshi
DC.publisher	Elsevier Ltd
DC.language' scheme='DCTERMS.RFC1766	English
DCTERMS.issued' scheme='DCTERMS.W3CDTF	2025-01-01
DC.identifier	https://doi.org/10.1016/j.ijmachtools.2024.104235
DC.subject	Finite element
	Forging
	Linear friction welding
	Microstructure
	Numerical modeling
	Plastic flow
	Pressure-controlled
	Steel
DC.description	Shotri R., Miura T., Geng P., et al. Understanding thermal-mechanical variations and resulting joint integrity of pressure-controlled linear friction welding of thin-steel sheets. International Journal of Machine Tools and Manufacture 204, 104235 (2025); https://doi.org/10.1016/j.ijmachtools.2024.104235.
DCTERMS.abstract	Linear friction welding is a solid-state joining technology that bonds materials via friction heating and plastic deformation. This process is being extensively researched for welding metallic sheets with different dimensions; however, it involves difficulties in joining thin cross-sections due to extensive misalignment and unsteady plastic extrusion of softened materials at interfaces. This study introduces novel efforts for joining thin cross-sections through pressure-controlled oscillations and displacements, facilitating localized plastic flow essential for high-strength solid-state bond formation. This method is rare, and the results reveal base metal fractures in tensile-tested welded joints of 2 mm thick S45C steel sheets. The interfacial yielding at specific temperatures is obtained by applying pressure corresponding to the temperature-dependent strength of the material. Accordingly, the welding is attempted using a hydraulic-based clamping system designed to accommodate large sheet lengths while allowing precise control of the interface pressure and temperature to facilitate controlled material plastic discharge. However, the requisite joint evolution tracking remains infeasible due to the intricate weld designs and is instead uncovered through novel numerical investigations. Modeling simultaneous oscillations and forging displacement while maintaining pressure depicted the kinetics of continual interfacial deformation. The transient fluctuations in plastic stress and temperature increments distinguish the stages of forging under different conditions. The computed temperature vs. plastic strain and the measured change in interfacial microstructures from martensite to dynamically recrystallized very fine ferrite with fragmented small cementite explain the lower temperature welding for an increase in applied pressure, enhancing the understanding of linear friction welding of thin steel sections for industrial applications.
DC.rights	This article is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.
DC.format	100215
citation_title	Understanding thermal-mechanical variations and resulting joint integrity of pressure-controlled linear friction welding of thin-steel sheets
citation_author	Shotri, Rishabh
	Miura, Takuya
	Geng, Peihao
	Morisada, Yoshiaki
	Ushioda, Kohsaku
	Fujii, Hidetoshi
citation_publisher	Elsevier Ltd
citation_language	English
citation_date	2025-01-01
citation_journal_title	International Journal of Machine Tools and Manufacture
citation_volume	204
citation_firstpage	104235
citation_doi	https://doi.org/10.1016/j.ijmachtools.2024.104235
citation_public_url	https://hdl.handle.net/11094/100215

Understanding thermal-mechanical variations and resulting joint integrity of pressure-controlled linear friction welding of thin-steel sheets

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