The temperature distributions, microstructure, and mechanical properties of tungsten composite with aluminum alloy friction-welded joints are presented in this paper. The effects of welding parameters on flash diameter, shortening, joint efficiency, microhardness, and microstructure were studied. Empirical temperature models for heating and cooling phases are proposed in this study. The predicted maximum temperatures at the periphery and in the axis of aluminum specimens were close to 550 °C and 480 °C at the interface, respectively. Moreover, the peak temperature in the weld zone was studied analytically. A maximum tensile strength of 234 MPa was reached for the following welding parameters: friction time of 3.5 s and friction force of 12.5 kN. The efficiency of the welded samples decreased after reaching the maximum value, with an increase of friction time and force. Maximum hardness at the interface and the half-radius reached 100 HV and 80 HV in the aluminum alloy joints, respectively. Dynamic recrystallisation areas on the aluminum alloy side were observed. Transmission electron microscopy observations of the microstructure in the aluminum alloy revealed the presence of a high dislocation density compared to the parent material.
Keywords: TEM; W-Ni-Fe composite; friction welding; temperature distribution.