Linear Friction Welding (LFW) is a uniquely important manufacturing process because it allows welding of dissimilar materials without filler material. In this study, bi-metallic Ti6Al4V-CoCrMo joints were manufactured using LFW process and analyzed the weldability and bonding strength. Ti6Al4V and CoCrMo cylinders were manufactured to a standard size of tensile specimens and cut into two identical pieces. The surfaces to be welded were polished and cleaned before performing welding. The experimental thermal data was recorded with an IR camera.

In the thermal stress simulation model, the temperature-dependent thermal properties of Ti-6al-4V were used. The thermal properties of CoCrMo were assumed constant due the fact that CoCrMo does not change phase until it reaches its melting temperature. The heat losses due to radiation was different for each workpiece because both materials had a different emissivity and the heat loss by convection is a function of the surface temperature by natural convection. The left boundary of the Ti-6Al-4V and the right boundary of the Co-Cr-Mo workpiece were constrained at a constant temperature of 45°C. The maximum deformation of the simulation model is well matched with the measured data within 5% error.

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