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<p>Conventional rotary friction welding, also known as linear friction welding, utilizes a single axial forging mechanism. However, this mechanism concentrates frictional heat near the outer periphery of the faying interface and produces a non-uniform radial temperature distribution. As a result, the consistency of material plastic flow decreases. Because the external force acts only in the axial direction, the controllability of weld formation and material flow remains limited. The process parameters are strongly coupled, and the joint quality is highly sensitive to variations in rotational speed and axial pressure. This sensitivity induces residual stress and reduces the reproducibility of joint quality. In this study, a CNC turning machine–based rotary friction welding process with two-axis motion control is introduced. This approach promotes coordinated multi-directional plastic flow and improves weld formation stability and overall joint quality. Under single-axis feeding, severe radial temperature gradients occur. The outer region reaches 275&#xa0;°C, whereas the center reaches only 175&#xa0;°C. The peak temperature difference reaches 97.6–100&#xa0;°C after 40&#xa0;s of welding. Dual-axis feeding improves thermal uniformity. The overall temperature difference decreases to approximately 70&#xa0;°C. The dual-axis single-reciprocal mode further reduces the peak difference to 18.1&#xa0;°C. Mechanical performance correlates with temperature distribution. Bending strength increases by 7.8%. Surface hardness improves by up to 4.5% from 75.3 Shore D. The bonding area increases from 55.42% to 93.98%. These results confirm that optimized dual-axis motion enhances heat distribution. It improves bonding integrity and overall weld quality. These findings support Sustainable Development Goal (SDG) 9 and SDG 12.</p>

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Enhancing the Temperature uniformity at the joint interface in rotary friction welding through welding process control

  • 期刊论文

  • 发表日期：

    2026年5月28日

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  • Chil-Chyuan Kuo,
  • Hong-Wei Chen,
  • Yu-Hong Feng,
  • Armaan Farooqui,
  • Song-Hua Huang

摘要

Conventional rotary friction welding, also known as linear friction welding, utilizes a single axial forging mechanism. However, this mechanism concentrates frictional heat near the outer periphery of the faying interface and produces a non-uniform radial temperature distribution. As a result, the consistency of material plastic flow decreases. Because the external force acts only in the axial direction, the controllability of weld formation and material flow remains limited. The process parameters are strongly coupled, and the joint quality is highly sensitive to variations in rotational speed and axial pressure. This sensitivity induces residual stress and reduces the reproducibility of joint quality. In this study, a CNC turning machine–based rotary friction welding process with two-axis motion control is introduced. This approach promotes coordinated multi-directional plastic flow and improves weld formation stability and overall joint quality. Under single-axis feeding, severe radial temperature gradients occur. The outer region reaches 275 °C, whereas the center reaches only 175 °C. The peak temperature difference reaches 97.6–100 °C after 40 s of welding. Dual-axis feeding improves thermal uniformity. The overall temperature difference decreases to approximately 70 °C. The dual-axis single-reciprocal mode further reduces the peak difference to 18.1 °C. Mechanical performance correlates with temperature distribution. Bending strength increases by 7.8%. Surface hardness improves by up to 4.5% from 75.3 Shore D. The bonding area increases from 55.42% to 93.98%. These results confirm that optimized dual-axis motion enhances heat distribution. It improves bonding integrity and overall weld quality. These findings support Sustainable Development Goal (SDG) 9 and SDG 12.