Residual stress prediction for the inertia welding process

Predictions of residual stresses in inertia friction welded Ni-base superalloys have been carried out using a commercial finite element code (DEFORM) combined with an energy balance approach and a 2D axisymmetric formulation. A coupled thermal and mechanical finite element model has been created. During inertia welding trials of RR1000, a high γ′ Ni-base superalloy, the rotational velocity and upset history curves were recorded. From these data the heat flux (the rate of energy input) through the weld interface was inferred and together with the upsetting rate input into the model as evolving boundary conditions. The coupled thermal and mechanical analysis leads to the prediction of the thermal history and the residual stresses generated during cooling. The validation of the model has been undertaken by comparing the predicted residual stresses with those measured using neutron diffraction. The comparison between predicted and measured stresses is in good agreement.