Ain Shams Engineering Journal xxx (xxxx) xxx

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Ain Shams Engineering Journal

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Experimental and analytical investigation on friction welding dissimilar

joints for aerospace applications
R. Ramesh Kumar a,⇑, J.M. Babu a, Bahaa Saleh b, H. Fayaz c, A. Chandrashekar d, Tanya Gera e,⇑,
Kottakkaran Sooppy Nisar h,⇑, C Ahamed Saleel g
a
Vel Tech Rangarajan Dr.Sagunthala R&D Institute of Science and Technology, Chennai, India
b
Department of Mechanical Engineering, College of Engineering, Taif University, P.O. Box 11099, Taif 21944, Saudi Arabia
c
Modeling Evolutionary Algorithms Simulation and Artificial Intelligence, Faculty of Electrical & Electronics Engineering, Ton Duc Thang University, Ho Chi Minh City, Viet Nam
d
Department of Mechanical Engineering, Bangalore Institute of Technology, Bengaluru 560004, India
e
Chitkara University Institute of Engineering and Technology, Chitkara University, Punjab, India
h
Department of Mathematics, College of Arts and Sciences, Wadi Aldawaser, 11991, Prince Sattam bin Abdulaziz University, Saudi Arabia
g
Department of Mechanical Engineering, College of Engineering, King Khalid University, PO Box 394, Abha 61421, Saudi Arabia

a r t i c l e i n f o a b s t r a c t

Article history: Friction welding is a method of joining two materials in solid-state that have a good bonding connection.
Received 30 September 2021 The materials are eventually joined by continuous acts of forging pressure combined with rotational
Revised 12 March 2022 drives by varying parameters such as friction pressure, forging pressure, friction time, rotation speed
Accepted 24 May 2022
and upset time. Low input heat and high contact bonding were the characteristics of this process. In this
Available online xxxx
present work, micro hardness and structural analyses of friction welded joints were investigated exper-
imentally, effect of process parameters on properties and temperature distribution were evaluated using
Keywords:
ANOVA and were compared with Finite element analysis using ANSYS R16.2. The results were in good
Friction welding
Ti-6AL-4V
agreement with each other. The friction time was 5 s, the rotation speed was 2100 rpm, the friction pres-
SS304L sure was 80 MPa, and the forging pressure was 84.5 MPa, all of which were optimal process parameters,
Micro hardness resulted in sound joints.
Finite element analysis Ó 2022 The Authors. Published by Elsevier B.V. on behalf of Faculty of Engineering, Ain Shams University
ANOVA This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).

1. Introduction
Dissimilar welding exhibits hybrid properties at two different
sides, results in enhanced system performance with cost reduction
and it is considered as one of the best engineering solutions in
multi materials processing. Dissimilar welding has already been
used in the fields of automobiles, aerospace, cryogenics, nuclear
systems and also in variety of engineering applications [1–4]. In
many circumstances, it is very challenging to produce sound/
strong metallurgical joints, due to different chemical and physical
properties of two metals. Solid state welding process such as Fric-
⇑ Corresponding authors.
E-mail addresses: ramesh.mech37@gmail.com (R. Ramesh Kumar), tanya.
gera@chitkara.edu.in (T. Gera), ksnisar1@gmail.com (K.S. Nisar).
Peer review under responsibility of Ain Shams University.
Production and hosting by Elsevier
tion welding has already proved feasibility to weld different dis-
similar materials’ combinations [5]. In this process, mechanical
energy is transmitted into thermal energy. The generated heat is
passed through the multiple directions of the particles. Operation
is established under two stages namely the heating stage and
upsetting [6]. Initially, the heating stage acts on contact between
the rotating and non-rotation side rods with applied pressure, later
upsetting takes place. In past, researchers were addressed the most
influenced process parameters and their influence on properties of
the friction welded joints [7,8]. Niyazi Cavusoglu [9] studied fric-
tion welded joints of inconel 713C and AISI 4140 joint and measure
the influence of friction pressure & time, forging pressure & time
on mechanical and metallurgical properties. Their results revealed
that, the thermo-mechanically affected zone was the strongest
zone of the weld, exhibited highest strength and hardness. EDS
analysis reveals the formation of the c00 -Ni3Nb phase at the grain
boundaries as c and c0 -Ni3 (Al, Ti) phases were observed in the
matrix were welded. Hardik D. Vyas et al. [10] investigated
Copper-Stainless Steel pipe joints welded by continuous drive fric-
tion welding under two friction times of 10 s and 15 s. Investiga-
tors found that friction time of 15 s yielded superior inter atomic

https://doi.org/10.1016/j.asej.2022.101853
2090-4479/Ó 2022 The Authors. Published by Elsevier B.V. on behalf of Faculty of Engineering, Ain Shams University
This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).

Please cite this article as: R. Ramesh Kumar, J.M. Babu, B. Saleh et al., Experimental and analytical investigation on friction welding dissimilar joints for
aerospace applications, Ain Shams Engineering Journal, https://doi.org/10.1016/j.asej.2022.101853
R. Ramesh Kumar, J.M. Babu, B. Saleh et al. Ain Shams Engineering Journal xxx (xxxx) xxx

diffusion which may lead to enhanced metallurgical bonding. The under peak rotational element circumstances [22]. Structural
reaction layer thickness of 17.28 lm and 1.21 lm were observed mechanics formed as heat transfer rate with low forging pressure.
for joints under 10 s and 15 s respectively, which influences the This structural shape formation is developed with the good
bonding and mechanical properties of Cu-SS friction welded joints. mechanical strength of materials [23]. In the case of dissimilar
Ateekh Ur Rehman et al. [11] studied the effect of welding process material joining, strength expands the thermal coefficient and
on structure and mechanical properties of friction welded Ti-Al- material hardness, which depends on the pressure, ranges [24].
4V/Nitinol. Structural analysis revealed flash formation on the Ti- In published articles on friction welding for dissimilar joints, the
6Al-4V side due to a reduction in flow stress at high temperatures focus is primarily on the friction welding process parameters and
during friction welding and fine grains near the Ti-6Al-4V interface how to optimize them for maximum joint strength. In addition,
due to dynamic recrystallization and strain hardening effects. The the majority of them are examined for solid rod configurations,
formation of intermetallic compounds in the weld interface makes whereas only a handful being investigated for pipe joint configura-
the joint to fail when it is subjected to tensile test. Yu Sik Kong et al tions. There is no systematic analysis performed that studies in
[12] were used online monitoring of acoustic emission system to
find the optimum welding condition for achieving quality joints
of Inconel 718 and molybdenum steel. They were noticed high
voltage with 0.44 MHz and 0.54 MHz frequency during friction
time and low voltage with 1.56 MHz and 1.74 MHz frequency
when it reached upset stage of friction welding. Similarly, Luca Rai-
mondi et al. [13] were also developed a novel monitoring system
able to collect in-process data and to interpret how could the weld
parameters affect the weld geometry and the dynamically evolving
thermo-mechanical conditions of the weld. Kumar et al. [14] mea-
sured the tensile characteristics of dissimilar metal friction weld-
ing of Ti-6Al-4V –SS304L. They were prepared joints by varying
process parameters and strength was evaluated for the same to
optimize. Amborish Banerjee et al. [15] investigated continuous
drive friction welded AISI-8630 steel to measure the effect of pro-
cess parameters on their structural and mechanical properties.
They conveyed that the maximum strength-to-ductility and static
toughness were obtained for the highest rotational speed (1200–
1400 rpm), maximum friction force (375–425 kN) and an interme-
diate forge force (600–650 kN) respectively. Geng et al. [16] were
developed a numerical modeling of linear friction welding of super
alloys to observe the plastic flow and interfacial self cleaning dur-
ing welding. Winiczenko et al. [17] studied the friction welding of
dissimilar Al/Mg alloys via. genetic algorithm to optimize welding
process parameters. Investigators were intended to maximize the Fig. 1. Schematic view of the positioning of the materials before friction welding.

tensile strength by varying process parameters. Pandia Rajan

et al. [18] investigated the effect of thermal and friction produced
in the SA 213 tube to SA 387 tube plate during the friction welding
process by using an external tool (Tungsten carbide). They used
two different techniques such as with hole and without hole to
estimate and found that the stress and ultimate heat flux values
of 18,782 MPa & 0.80475 W/mm2 for with hole and 10,486 MPa
& 1.1344 W/mm2 for without hole respectively. Rehman et al.
[19] were investigated for optimizing process parameters of
Inconel 718 and Inconel 600 joints welded by rotary friction weld-
ing. Ramesh kumar et al. [20] was concentrated on the heat dissi-
pation during friction welding of dissimilar metals such as
titanium alloy and stainless steel. They were majorly focused on
the heat zones formation under friction. Similarly, Kumar et al.
[21] analyzed the friction welded Ti-6Al-4V and SS304L joints for
their joint effect and integrity. The mechanical bonding structure
is gradually improved by heating moments with temperature.
Fig. 2. Aluminum coated specimens welded by friction welding-case (a).
The dissolving stress is created at room temperature and achieved

Table 1
Experimental Trials with a different set-up.

Sl. No. Friction pressure
MPa
1 40
2 45
3 50
4 55
5 60
Friction time Forging pressure Forging time Speed
Sec MPa Sec (rpm)
5 45 5 1800
4 40 4 1600
5 55 5 2100
4 70 5 2300
4 80 4 2500

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R. Ramesh Kumar, J.M. Babu, B. Saleh et al.
case of Ti-6AL-4V/SS304L pipe joints. The microstructure evolu-
tion, effect of factors on properties, temperature distribution under
different processing conditions of friction welding is also not inves-
tigated so far. Additionally, the correlation between experimental
and FE analysis of joint properties is very much interesting to
establish scientific understanding, which is hitherto not investi-
gated systematically in case of Ti-6AL-4V/SS304L FW joints. There-
fore, it is worthwhile to study the friction welded dissimilar Ti-
6AL-4V/SS304L pipe joints. In this study, microstructure and micro
hardness variations at the interface region, as well as the effect of
factors on temperature and stress of Ti-6AL-4V/SS304L pipe fric-
tion welded joints (welded under changing parameters), are ana-
lyzed and correlated.
2. Experimental details
In the present investigation, two dissimilar metals were used
such as Ti-6AL-4V and SS304L to friction weld. Each specimen is
Fig. 3. Friction welded samples without Al coating – case (b).
Fig. 4. Meshed Models of Ti-6AL-4V and SS304L.
Fig. 5. Boundary conditions with connections.
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Ain Shams Engineering Journal xxx (xxxx) xxx
having 50 mm length and 16 mm diameter. The specimen’s welded
distances were measured equally at 5 mm between the end and
the middle stage. Total five specimens were friction welded by
varying process parameters (shown in Table 1). Experimentation
was conducted under two conditions: (a) without interlayer but
SS304L & Ti-6Al-4V are coated with aluminium (b) with interlayer
but not coated with aluminum. In case (a) aluminum coating itself
is acting an interlayer between titanium and stainless steel. The
linked sample ranges and melting areas of different locations were
measured together. With the help of process analysis software,
transferred heat temperatures are measured, and the various ther-
mal transfer levels of the sampled sites are checked. The welding
progression is required for the better forging of endurance machine
setups. To travel the forging pressure with the bulge areas, time
possession is significant. The mixing of heat transfers and molecu-
lar structures are identified the symmetrical responses from the
mechanical parameters. Reduced corrosion, high tensile strength,
temperature resistance, and ecofriendly are the characteristics of
stainless steel and Titanium is excellent in corrosion, light weight,
high strength, easy temperature rise and superconductivity.
Aluminum interference mixtures were formed into chemical
compositions. The friction heat temperature of 700–800 °C is pri-
marily associated with aluminum and titanium specimens. The
samples were eventually cut to an aluminum length of 5 mm from
the bulged joints. The system configuration was gradually rear-
Location 1
350 Location 2
Location 3
300
250
Hardness at SS-Al
200
150
100
50
0
1 2 3 4 5
Specimen Number
Fig. 6. Micro hardness values measured at SS-Al interface at different locations.
R. Ramesh Kumar, J.M. Babu, B. Saleh et al. Ain Shams Engineering Journal xxx (xxxx) xxx

ranged with parameters of aluminum and steel. This relation
requires a forging pressure of 1500 °C and 45 MPa. A joint sample
is described in Fig. 1 to test the Hardness Analyses. Best concentra-
tion binding structures are given for hardness evaluation tests
shown in Fig. 2.
3. Finite element modeling
Finite element (FE) methods calculate the defining limitation of
thermal heat transfer. FE method is adapted the interconnecting
node elements with discrete. Better solutions have been imple-
mented with computational heat transfer method of heat transfer
and structural analysis. The two different ends of the specimen are
used in specific boundary conditions. The technology for process
analysis allows in predicting better contact regions concerts. The
initial setup methods [25] apply different boundary conditions
and forging pressures; various ways of solving thermo mechanical
problems are described by symmetrical replications. Temperatures
of HAZ are determined and measured by experimental results.
3.1. Geometry & meshing

The 16 mm diameter and length of 50 mm width were built-in

Location 1
500 three-dimensional models (Fig. 3). Technology for process analysis
Location 2
imports a 3D model [22]. For the three-dimensional template
Location 3
Tetrahedron, a mesh component is used (Fig. 4). Suitable contact
400 surfaces are designed for the mesh component models. The analy-
sis approaches are carried out by computer heat transfer and static
Hardness at Al-Ti

structural analyzes. The strength of non-linear analysis developed

300 interface materials. Fixed supporting, rotating moment, and forg-
ing pressure are needed for limiting conditions. Better quality of
mesh elements is demonstrated with the result of contact surfaces
200 [26]. The material bonded strengths are established with non-
linear material. Fig. 5 shows the different material properties and
boundary conditions are represent the symmetrical contacts.
100
3.2. Boundary conditions

0 The titanium metal end side is set to the displacement bound-

1 2 3 4 5
ary conditions and forging stress, and rotational elements are
Specimen Number added to the end side of the stainless steel material. The rotating
area involves forging pressure and the pressure applied. For non-
Fig. 7. Micro hardness values measured at Al-Ti interface at different locations.
rotational side elements, all X, Y, Z coordinates are fixed. In the

Fig. 8. (a) Default ferrous particles (b) default Austen particles (c) grain surfaces (d) interface surface.

4
R. Ramesh Kumar, J.M. Babu, B. Saleh et al. Ain Shams Engineering Journal xxx (xxxx) xxx

Fig. 9. (a) & (b) SEM interlayer’s at different locations.

Table 2
Temperature Distribution on ANOVA table.

Run Actual Predicted Residual Internally Studentized Externally Studentized Cook’s Influence on Fitted Value Standard
Order Value Value Residuals Residuals Distance DFFITS Order
1 128.43 163.39 34.96 1.052 1.058 0.094 0.689 11
2 139.67 163.39 –23.72 0.714 0.697 0.043 0.454 6
3 168.40 163.39 5.01 0.151 0.144 0.002 0.094 7
4 240.50 247.40 6.90 0.333 0.319 0.059 0.518 12
5 380.70 323.32 57.38 1.584 1.719 0.099 0.764 3
6 392.60 323.32 69.28 1.912 2.231 0.145 0.992 9
7 398.80 381.66 17.14 0.527 0.509 0.027 0.354 14
8 402.50 449.62 47.12 1.349 1.408 0.105 0.757 5
9 442.30 449.62 7.32 0.210 0.200 0.003 0.108 13
10 468.70 482.28 13.58 0.417 0.401 0.017 0.279 1
11 487.90 542.28 54.38 1.501 1.605 0.089 0.713 2
12 540.20 542.28 2.08 0.057 0.055 0.000 0.024 15
13 552.60 549.26 3.34 0.161 0.153 0.014 0.250 8
14 590.80 601.31 10.51 0.316 0.303 0.008 0.197 4
15 612.53 601.31 11.22 0.338 0.324 0.010 0.211 10
16 638.49 601.31 37.18 1.119 1.134 0.106 0.739 16

Fig. 10. Plot Effects.

5
R. Ramesh Kumar, J.M. Babu, B. Saleh et al. Ain Shams Engineering Journal xxx (xxxx) xxx

non-rotational side start, constant rotational speed was involved. 4. Results and discussion
All boundary conditions are applied and shown in Fig. 13. With
the aid of ANSYS 16.2 edition, these boundary conditions and 4.1. Micro hardness and structure
meshed elements are assisted.
Figs. 6 & 7 shows micro hardness values measured on SS-Al
interface and Al-Ti interface at different locations of friction

3.3. Material conditions

The curved stress–strain ratio was developed into traditional

thermo-mechanical methods and equations of Johnson-cook. Due
to some changing plastic deformation and heat transfer conditions,
the rotational elements are performed. For room temperatures, all
these heat conditions are resolved. The formulation of the Johnson-
cook temperature test state was carried out in the heat transfer
conditions of materials. For welding joint development, heating
time with room temperatures is carried out. Physical measure-
ments and symmetrical information’s are carried out under terms
of the heat-affected area. Non-linear output and convergent stages
produce melting characteristics [27].

    m 
e1 T  T room
r ¼ ðA þ Ben Þ 1 þ Cln 1 þ 1 ð1Þ
e2 T melt  T room

where, r is flow stress, A is the yield stress of the material at room

temperature (MPa), e is plastic strain, n is strain hardening expo-
nent, C and m are the strain rate hardening and thermal softening
coefficient, Troom and Tmelt are room temperature, and melting tem-
Fig. 12. Actual vs. Predicted results of welded samples.
perature, e1 & e2 are effective strain rate, and reference strain rate
respectively.

Fig. 11. Residual plots.

6
R. Ramesh Kumar, J.M. Babu, B. Saleh et al.
welded specimens at room temperature. Specimen 1 demonstrated
highest hardness of 341 Hv at location 2 of SS-Al interface of the
friction weld specimen 1. As well, specimen 4 showed least hard-
ness at location 2 of SS-Al interface of the friction weld specimen
4. Better quality outcomes in bonded structures are obtained under
the heat-affected area parametric shapes. These well bonded struc-
tures show symmetry phase area a result of hardness predicts the
molecular joint. Specific end-case results show that melt structures
precipitate.
Friction welded specimens were subjected to structural analysis
using optical microscope (Fig. 8) and scanning electron microscope
(Fig. 9). Aluminum interacts with related structures and displays
the effects were visualized. The high contact regions and improved
performance of steel and aluminum particles were easily observed
bonded. The best formulation at constant time and with significant
upsetting pressure is shown schematically. Distances of 10 lm are
created from different samples with high precision images. From
the variation of symmetry results are evaluated and performed in
the gap of dissimilar joints. Fig. 9 show the microstructure images
by scanning electron microscope for titanium alloy and stainless
steel friction welded specimen. The compositions of stainless steel
and titanium are the specific boundary conditions in various
places.
4.2. Analysis of variance
In dissimilar materials with structural contact, frictional forging
pressure and time-changing parameters are involved. For ANOVA
Fig. 13. Temperature distribution on different trials.
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Ain Shams Engineering Journal xxx (xxxx) xxx
table distributions, the experimental values are executed by the
symmetrical ranges. Table 2 displays the preliminary results of
the ANOVA test.
Figs. 10 & 11 demonstrates the means and residual plots of
ANOVA for experimental input values. Mean effect optimum values
are predicted the range of heat affected zone, affected zone and not
affected zone. Friction pressure mean effect values are acted from
170 Mpa to 480Mpa. In the particular region it achieved the better
combination structures and shapes. Friction time effect is opti-
mized the variations of 20 sec to 10 sec reduced. The good contact
behaviors are formed from the 1300 rpm of rotation to 1600 rpm.
The optimized data ranges of experimental results are given good
contact joints between the stainless steel to titanium side. With
the support of the most progressive plot values, different position
values are predicted. The mean and variance value stable consist of
the higher, middle, and lowest constraints rates. The best results
are given in analytical parametric configuration as analytical input
tests are verified for the experimental setup values. Relative to
mean, effective results and experimental pressure values are com-
pared successfully. Non-linear segments establish the stress–strain
ratio of metallurgical formation. The better components of material
joints are formed from various heat energy sources. The improved
performance and functionality of the extra features are shown in
between the symmetrical contacts.
The experimental results are compared with analytical stresses
equally maintained the results, demonstrated in Fig. 12. The results
obtained through an aluminum interlayer technique showed good
agreements with each other. Temperature distribution results are
R. Ramesh Kumar, J.M. Babu, B. Saleh et al. Ain Shams Engineering Journal xxx (xxxx) xxx

Fig. 13 (continued)

performed in the form of critical factor (Fcrit), fishers ratio (F), mean tion time and speed values are analyzed. Rotational speed devia-
square, degrees of freedom (df), the percentage of contribution (P), tions the endurance is reduced and the frequency is increased.
and Sum of square (SS) values, as demonstrated in Table 2 [28]. The
samples identified are shown in Table 2 with most critical values.
4.3. FE analysis
The actual and predicted result comparison is shown in Fig. 12.
Aluminum interlayer technique is suggested as better strength
4.3.1. Parameter effects on equivalent stress
and good bulged areas. Normal welded tensile results are shown
Various test simulation results from ANSYS 16.2 workbench are
52.65 Mpa, but aluminum interlayer used tensile result is shown
performed. Confident grades of static structural elements are
67.39 Mpa. It is achieved 1.28 % higher from as normal welding
checked with different samples and results in better stress equiva-
technique. With the support of mean useful plots, equivalent fric-
lent. Titanium and stainless steel particles are conducted under
8
R. Ramesh Kumar, J.M. Babu, B. Saleh et al.
these similar test conditions with mixed parameters. For different
test areas, various velocity-changing conditions are conducted.
Results of Trial 6 deformation are performed, and enhanced perfor-
mance of similar structures is presented. Total levels of joining
parameters are shown to be better structures in combination with
distortions. A temperature variations and mechanisms of deforma-
tion are shown in Fig. 13.
4.3.2. Parameter effects on the temperature distribution
Significant values are given as inputs in various boundary setup
conditions from the ANOVA table. These tests demonstrate the best
performances of maximum stress and deformations. The confi-
dence levels are compared with the results of the experimental
setup as more than 70% is provides the symmetrical comparisons.
The corresponding stress tests are conducted with the best correla-
tion of the principal stresses. Such actions are named as determina-
tion of location, and results are shown in Fig. 14. All configuration
tests of parameters are combined with total deformation and dif-
ferent elongations. Continuous test functions are done with equal
structural foundation and structural deformation. With the basis
of varying speed contacts, all test results are gradually increased.
Fig. 14 displays all the different test sample maximum principal
stress outcomes. The gradient of temperature will combine two
different processes of material. These check valves are the sum of
the lengths of the joined materials.
Fig. 14. Maximum principal stress results for nine sets of trials.
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Ain Shams Engineering Journal xxx (xxxx) xxx
Due to frictional contact, the initial stage of materials creates
the fire point in both end faces. Later adjusting the velocity and
increased pressure due to more frictional interactions, the ele-
ments are applied at the fire point. These methods defined the
expansion measures. The attached materials distance and changing
effects of temperature are shown in Fig. 15.
4.3.3. Parameter effects on total deformation
Unique pressure is applied due to magnificent principal stres-
ses, and von misses stresses. It is performed in all directions of
equal strengths. Endurance limitations are performed in normal
principal stresses with forging pressure. Different trial perfor-
mances are acted in equilibrium conditions with constant pressure.
The stress parameters of forging initially move across different sur-
faces of contact. This approaches the high revolution of contact
surfaces with certain velocity changes. Three separate stages func-
tion, such as fire point, flash point, and melting point. The dissim-
ilar joints are connected to the melting point stages as quickly as
possible. Within graphical configurations, the different samples
and parameter ranges are shown. Different materials are related
to forging pressures by changing speed and increasing tempera-
tures. In good analytical statements and better deformation tests,
the regions of the melting sample are carried out. The effects of
graphic quality are the best-combined methods and weaknesses.
R. Ramesh Kumar, J.M. Babu, B. Saleh et al. Ain Shams Engineering Journal xxx (xxxx) xxx

Fig. 14 (continued)

10
R. Ramesh Kumar, J.M. Babu, B. Saleh et al.
Fig. 15. Distance vs. temperature of welded samples.
4.3.4. Parameter effects on equivalent stresses
Sectional views in the form of a heat transfer are shown, which
leads to two ends unique. Shear stresses are applied to different
ends of the material. The thermal area is influenced by the different
characteristics and the behavior of the materials. The initial mate-
rials were converted into plasticized materials in the heat zones.
The components of deformation are 15.7 percent less than ordinary
forms. Different materials of Ti-6AL-4V and the SS304L include
internal energy and hourglass energy output rates. The number
of rotational cycles increased based on cyclic power. There are var-
ious HAZ parameters for contact energy and kinetic energies.
Fig. 16 displays all specimens with changing energy conditions.
4.3.5. Parameter effects on sliding contacts
For equal heat transferred surfaces, the result for ANSYS static
structural analysis is recorded. For better quality of new joint
forms, the product’s elastic mechanical properties are achieved.
Better performance of equal strength with new material coordina-
tion is demonstrated in adhesively bonded techniques. The sliding
contacts of deformed materials with structural effects are shown in
Fig. 17.
4.3.6. Welded sample results with constant upset time
When integrating frictional process techniques, different num-
bers of trails are shown. These laboratory exercises are conducted
at different pressures with constant temperature. Fig. 18 shows the
forging pressure applied with varying upset time. Test 1 is con-
ducted with 30 MPa forging pressure and 3 s of friction time. Yet
results are obtained in much less wired connections in this exper-
imental setup. Test 6 samples with a forging pressure of 95 MPa
with a friction time of 3 sec for good bonding strength are per-
formed. For all the different test samples, the system speed is con-
tinuously maintained at 1600 rpm. The statistic in 25 indicates of
the sampled trials are provides better symmetrical results.
During the experimental setup, the machine speed increased
from 1600 rpm to 1800 rpm. Moreover, all remaining parameters
are maintained constantly. Better combined structures are given
from this experimental setup for the better performance of test
trial 6. Fig. 19 shows forging pressure with friction time.
The system frequency varies from 1800 to 2000 rpm in the
rotating speed parameters. The same pressure and friction times
are maintained at this point. The values of test 6 are shown in good
11
Ain Shams Engineering Journal xxx (xxxx) xxx
bonding strength and simple bulge types relative to other speci-
mens. Fig. 20 shows the forging pressure with friction time.
At 2400 rpm, the speed rates are increased, and the output of
the remaining parameters is continuously maintained. All experi-
ments are similar bonding systems, and the finding of test trial 6
minimizes bonding contacts gradually. The connecting structural
defects were observed from this experimental setup. The explana-
tion for this is that the bonding rate is increased, and the friction
time decreases slowly. All tests are shown unbounded, and output
values are shown in Fig. 21.
Using aluminum adhesive technique, all specimens are welded.
Fig. 22 shows all types of tensile test results. The levels of stress
contribution were achieved in improved elongation structures.
The correct design structures have appeared in the UTM system
results. Tensile tests from sample 2 are increased slowly, and cer-
tain levels are raised after the levels have been decreased gradu-
ally. The tests for sample 5 in tensile regions are conducted
slowly. The weak qualities of binding structures are resulted in
sample 3. The excellent quality structures with actionable tensile
characteristics are shown to remain. The adhesive methods used
for various joints were done using the aluminum interlayer to cre-
ate a good contact surface between titanium and steel. The exper-
imental and theoretical results were related to numerical and
graphical models are explained and compared to symmetrical
approaches. The workbench for process analysis allows obtaining
the stress results compared to the test. Fig. 23 shows load vs. stress
plot for deformation recorded during trials.
5. Conclusion
This research work shows a good friction welding process of
dissimilar materials for titanium (Ti-6AL-4V) and stainless steel
(SS304L). This research work conducts six different boundary con-
ditions and seven numbers of trials. Most of the boundary condi-
tions are changed from the initial values. The sixth set of
boundary conditions are provided good bond of joint and less
energy loss. The sixth frictional parameter results are friction pres-
sure is 70 MPa, friction time is 5 Sec, forging pressure is 70 MPa,
friction time is 5 Sec, speed 2200 rpm. These boundary setup
results provide better sliding contact and good mechanical bond-
ing. The stress-life factor results are showing the normal distribu-
tion of temperature gradients. It is recommended heat treatment
R. Ramesh Kumar, J.M. Babu, B. Saleh et al. Ain Shams Engineering Journal xxx (xxxx) xxx

Fig. 16. Number of cycles vs. different trials of energy.

12
R. Ramesh Kumar, J.M. Babu, B. Saleh et al. Ain Shams Engineering Journal xxx (xxxx) xxx

Fig. 17. Sliding contacts of deformed trials.

13
R. Ramesh Kumar, J.M. Babu, B. Saleh et al. Ain Shams Engineering Journal xxx (xxxx) xxx

Fig. 17 (continued)

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R. Ramesh Kumar, J.M. Babu, B. Saleh et al. Ain Shams Engineering Journal xxx (xxxx) xxx

Fig. 18. Forging pressure with varying upset time (first set of boundary conditions).

Fig. 19. Forging pressure with friction time (second set of boundary conditions).

Fig. 20. Forging pressure vs. friction time (third set of boundary conditions).

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R. Ramesh Kumar, J.M. Babu, B. Saleh et al. Ain Shams Engineering Journal xxx (xxxx) xxx

Fig. 21. Fourth set boundary conditions for different trials.

Fig. 22. Fifth set boundary conditions for different trials.

process must be removed of upset time and temperature gradients.

The fisher’s ratio reduction values are 43.8% of the original values.
In this, comparison results are generated the symmetric relation-
ship between titanium and stainless-steel.

Declaration of Competing Interest

The authors declare that they have no known competing finan-

cial interests or personal relationships that could have appeared
to influence the work reported in this paper.

Acknowledgment

The authors extend their appreciation to the Deanship of Scien-

tific Research at King Khalid University, Saudi Arabia for funding
this work through Research Group Program under Grant No: R.G.
Fig. 23. Load vs. Stress plot for deformation. P.2/129/43. The author B. Saleh is grateful to the Taif University
16
R. Ramesh Kumar, J.M. Babu, B. Saleh et al.
Researchers Supporting Project number (TURSP-2020/49), Taif
University, Taif, Saudi Arabia for the financial support.
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R.Ramesh Kumar is a research scholar at Vel Tech
Rangarajan Dr.Sagunthala R&D Institute of Science and
Technology. His areas of interest are CFD, welding,
Biodiesel.