Experimental and Numerical Investigation of Factors That Affecting in Frictional Welding of Mild Steel and Al alloy A356

Friction welding is one of the most advanced welding techniques in the world today, due to the ability of this technique to find weld specimens with high performance specifications. The present study deals with friction welding of similar metals (mild steel) and similar metals (aluminium alloy A356) for solid and hollow specimen, also the results were studied analytically methods using ANSYS(16) software program. The fracture force of standard specimens were 576.33 MPa and 105.41 MPa, while this force of welded specimens were 463.64 MPa and 69.04 MPa for mild steel and Al-A356 respectively with reduction about (30%) in equivalent stress values. The hardness was increased at the weld region as a results of the friction pressure and oxidation process and the differences in these value due to the metals nature and its crystal construction. The temperatures distribution in both practical and theoretical methods refers to the symmetrical distribution along the weld region. The fatigue sensitivity of two metals were showed that the minimum life in mild steel was (8523 cycle) while the minimum life in Al-A356 was (1713 cycle) under same load condition.