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<p>Inertial friction welding has been widely used in welding dissimilar metal materials due to its advantages in suppressing the formation of brittle phases and achieving controllable plastic flow. In this paper, the optimization of process parameters and the flash formation mechanism in inertia friction welding of 430/316L stainless steel were systematically studied. Using response surface methodology, this study determined the influence degree of welding parameters on the tensile strength of the joint, in descending order: friction speed, forging speed, forging pressure, and friction pressure. Under the optimized process parameters (friction speed 2750&#xa0;r/min, friction pressure 4&#xa0;MPa, forging speed 1350&#xa0;r/min, forging pressure 7&#xa0;MPa), the tensile strength of the welded joint was 520.5&#xa0;MPa. Based on the thermal–mechanical coupling simulation and high-speed photography experiment, the dynamic formation mechanism of the flash under the synergistic effect of the welding interface temperature field, stress field, and plastic flow field was systematically revealed: High interface temperature leads to metal softening, the high stress at the edge and the low stress in the middle drove the plastic metal flow, the axial velocity gradient (5.28&#xa0;mm/s at the top and 1.95&#xa0;mm/s at the root) caused the flash to curl upward, and the radial inward flow (− 3.61&#xa0;mm/s) intensified its bending toward the base metal side. The elucidation of this mechanism provided a direct theoretical basis for the active regulation of flash shape.</p>

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Numerical simulation and flash forming mechanism of inertia friction welding of 430/316L dissimilar stainless steel

  • 期刊论文

  • 发表日期：

    2026年5月4日

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  • Kaikui Zheng,
  • FanFan Jiang,
  • Wei Xu

摘要

Inertial friction welding has been widely used in welding dissimilar metal materials due to its advantages in suppressing the formation of brittle phases and achieving controllable plastic flow. In this paper, the optimization of process parameters and the flash formation mechanism in inertia friction welding of 430/316L stainless steel were systematically studied. Using response surface methodology, this study determined the influence degree of welding parameters on the tensile strength of the joint, in descending order: friction speed, forging speed, forging pressure, and friction pressure. Under the optimized process parameters (friction speed 2750 r/min, friction pressure 4 MPa, forging speed 1350 r/min, forging pressure 7 MPa), the tensile strength of the welded joint was 520.5 MPa. Based on the thermal–mechanical coupling simulation and high-speed photography experiment, the dynamic formation mechanism of the flash under the synergistic effect of the welding interface temperature field, stress field, and plastic flow field was systematically revealed: High interface temperature leads to metal softening, the high stress at the edge and the low stress in the middle drove the plastic metal flow, the axial velocity gradient (5.28 mm/s at the top and 1.95 mm/s at the root) caused the flash to curl upward, and the radial inward flow (− 3.61 mm/s) intensified its bending toward the base metal side. The elucidation of this mechanism provided a direct theoretical basis for the active regulation of flash shape.