Abstract
This study investigates the impact of temperature and pressure on friction welding, a solid-state joining technique. It uses simulation to analyze material behavior and properties during the welding process. The study aims to optimize welding conditions to improve joint strength and integrity. The results provide recommendations for maximizing parameters in practical applications, enhancing production procedures and enhancing decision-making. The simulation-based methodology also offers an economical and expedient method for investigating situations before experimental execution. The test rod, measuring 16mm in diameter and 100mm in length, was designed for two pieces. The simulation program was set up with timings and pressures, a fixed rotation speed of 1500 r.p.m., and the temperatures from the welding process were entered into an artificial intelligence SIMULIK program. The study reveals that the deformations of the materials being welded are directly influenced by the welding pressure. Greater force is given to the materials as pressure rises, which causes more plastic deformation. and longer times under frictional pressure can lead to higher temperatures due to increased heat generation from friction. This enhanced metallurgical bonding can result in a joint with improved fatigue strength. which can contribute to better fatigue resistance. Prolonged welding pressure helps in reducing stress concentrations at the weld interface. and the stress distribution will be more uniform, minimizing the likelihood of stress concentration points in the weld joints with fewer defects and improving resistance to crack initiation and propagation
