 Heat transfer:

The fundamental non-steady equation of Fourier’s heat conduction in the coupled thermo-
mechanical problem can be expressed as follows:
∂ T /∂t +u( ∂T /∂ x)=1 /ρ C p ∂/∂ x (k ∂ T /∂ x ) – h P / ρC p A( T −T o)+q ˙… (2.10)
where T is temperature, To is the ambient temperature around the rod, u is the shortening
velocity, ρ is the material density, Cp is the specific heat capacity, A is the cross-sectional area, P
is the perimeter of the rod, k is the thermal conductivity, h is the convection coefficient, x is the
distance from the weld interface and t is time. For simplicity, Eq. (7) can be rewritten as
∂ T /∂t +u(∂T /∂ x)=α ( ∂2 T /∂ x 2)−β(T −¿)+ q ˙…..………………. (2.11)
Where α =k / ρCp∧β=hP/ ρCpA .
In this one-dimensional equation, the convection term on the right-hand side of the equation
accounts for heat conduction and heat lost through convection along the lateral surfaces of the
two components. It is assumed that there is no heat lost through radiation at the frictional
interface. The problem of heat conduction in the whole process of friction welding determined
by means of Eq. (8) was, thus, simplified to the calculation of temperature field, T = T(x, t). The
calculation of the temperature of the friction welding process is carried out in two stages. The
first stage is the heating part while the second is the cooling process. The initial and boundary
conditions when solving Eq. (8) are expressed based on the two stages.
 Heating stage:
The temperature distribution is calculated for heating separately for the rod of length (L) by
assuming common average heat generated at the interface. For the heating stage, the initial and
boundary conditions for the simplified equation (8) are derived as
T ¿ h¿=¿ , for t h¿ 0 … … … … … … … … … … … … … … ..(2.12)
−k (∂ T /∂ x)=q , x=0 for t h¿ 0∧… … … … … … … … .(2.13)
−k (∂ T /∂ x)=h ¿o), x = L, for th > 0……………. (2.14)
Where th is the heating or frictional time, To is the initial temperature of the specimen, q is the
surface heat flux generated at the friction surface (x = 0).
 Cooling stage (welded):
At this stage the rods have been joined and considered as one new rod for the calculation, where
the initial and boundary conditions for the simplified equation (8) are derived as
T ¿ j, tc ¿=T n, for t c¿ 0∧… … … … … … … … … … … … … …( 2.15)
 Ks(∂T /∂ x)=ha(Ts−¿) , xj¿ 0 , for t c¿ 0 … … … … ....(2.16)
Where xj is the distance from left end of the joined rods, t c is the cooling time, ks is the thermal
conductivity of the steel, and T is the temperatures of the free surfaces of the steel. T n is the last
temperature profile from the previous heating stage. The only unknown in the equation presented
above is the shortening velocity (u) which is assumed to be zero. The calculation of the
temperature is carried out using FORTRAN.

Properties of Copper: The electrical conductivity of copper is 2nd only to silver. Its thermal
conductivity is 384 W/m K, is about twice that of aluminum. Copper is nonreactive and does not
rust or become brittle in sunlight, make it good in corrosion resistance (CopperSpecifications,
Properties, 2005). The yield point for copper is not sharply defined. As a result it tends to be
reported as either, a 0.5% extension under load or as 0.2% offset. Pure Cu has a melting point of
1084.62°C, and density of 8.96 g/cm3. It has a tensile strength from 172.5-345 MPa, depending
on if it is casted, annealed or cold-worked.

Table 3.4: Tensile properties of Copper ( Mohammad Iqbal Bin Abdul Aziz et al. 2012)
Material and conditions UTS (MPa) Efficiency (%) YS (MPa) Elongation (%)
Pure copper: BM 234 94 178 47