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This research investigates initial temperature control in Rotary Friction Welding (RFW) of dissimilar metals (C45 steel and AA1050 aluminum). Joining these materials offers significant performance and cost benefits, yet challenges arise from property disparities causing weld defects. To address this, we integrated high-frequency induction heating as a pre-welding stage in RFW to achieve uniform initial temperature distribution and reduce defects. COMSOL Multiphysics® software simulated both localized induction heating of C45 steel and subsequent heat transfer during contact welding, demonstrating effective heat concentration. Experimental trials, using a ZVS3000W circuit and MMA 200PRO welder, validated these simulations, confirming rapid heating of C45 steel to the desired plastic state, facilitating simultaneous material softening for optimal joining. Minor discrepancies between simulated and experimental data were noted, yet overall consistency affirmed the model’s predictive reliability. In conclusion, COMSOL Multiphysics® is a robust simulation tool, and the developed induction heating-assisted RFW system successfully enhanced weld quality and reduced defects. Recommendations include refining coil designs and enhancing automation for broader industrial application.

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Investigation of Initial Temperature Control in Rotary Friction Welding Using Induction Heating Assistance

  • 会议论文

  • 发表日期：

    2026年

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  • Huynh Vinh Loi,
  • Truong Quoc Viet,
  • Nguyen Hai Dang

摘要

This research investigates initial temperature control in Rotary Friction Welding (RFW) of dissimilar metals (C45 steel and AA1050 aluminum). Joining these materials offers significant performance and cost benefits, yet challenges arise from property disparities causing weld defects. To address this, we integrated high-frequency induction heating as a pre-welding stage in RFW to achieve uniform initial temperature distribution and reduce defects. COMSOL Multiphysics® software simulated both localized induction heating of C45 steel and subsequent heat transfer during contact welding, demonstrating effective heat concentration. Experimental trials, using a ZVS3000W circuit and MMA 200PRO welder, validated these simulations, confirming rapid heating of C45 steel to the desired plastic state, facilitating simultaneous material softening for optimal joining. Minor discrepancies between simulated and experimental data were noted, yet overall consistency affirmed the model’s predictive reliability. In conclusion, COMSOL Multiphysics® is a robust simulation tool, and the developed induction heating-assisted RFW system successfully enhanced weld quality and reduced defects. Recommendations include refining coil designs and enhancing automation for broader industrial application.