Abstract
Linear friction welding (LFW) is a kind of advanced manufacturing technology and used mainly in the manufacturing of aircraft engine bladed disks (blisks) currently. However, the residual stress evolution of TC17 titanium alloy during LFW is complex and its distribution is difficult to characterize. In this study, the residual stress of welding was studied using numerical simulation and experimental methods. The results showed that the maximum temperature on the welded surface was up to 1000 °C and the cooling rates in the lengthwise, widthwise, and normal direction with the same distance from the center of the weld were 456 °C/s, 448 °C/s, and 232 °C/s, respectively. The lengthwise stress on the welding surface was the largest, followed by the widthwise stress and normal stress. Among the three factors affecting welding stress, the upsetting force played a leading role, followed by the vibration amplitude and frequency of the welded parts. By optimizing the process parameters: upsetting force 18.2 kN, vibration amplitude 2.5 mm, vibration frequency 40 Hz, a 30% decrease of the maximum residual stress could be achieved compared to that without optimization. The residual stress before and after welding parameter optimization was measured by the contour method, and the measured results were in good agreement with the simulation results, which verified the effectiveness of parameter optimization on residual stress controlling.