Finite element modeling of hybrid friction diffusion welding of tube-tubesheet joints

Fadi Al-Badour*

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review


Hybrid Friction Diffusion Bonding (HFDB) is a solid-state welding process that proved its capability of producing sound tube-tubesheet joints, but with limitations on tube thickness (up to 1mm) and tube-tubesheet materials. In the petrochemical industry, there is a great demand for the use of carbon steel shell and tube heat exchangers. To investigate the feasibility of HFDB techniques in joining thicker tube (i.e 2.1 mm) on tubesheet joint, a three-dimensional thermo-mechanical finite element model (FEM) was developed and solved using ABAQUS (commercial finite element analysis (FEA) software). The model was used to predict the temperature distribution and developed stresses during and after welding. The model considered temperature dependent material properties while Johnson-cook model was used to govern material plastic flow behavior. In this paper,19 mm (¾ in) ASTM 179 cold-drawn carbon steel tube into an ASTM A516 Grade 70 tubesheet joints was simulated. Results are validated based on temperature measurements, which was found in good agreement with experimental results. The developed model can be used to optimize processing parameters (i.e. tool rotational speed, dwell time “holding time”, and forging force.. etc) and study their effect on material flow and developed stresses.

Original languageEnglish
Title of host publicationMaterials and Fabrication
PublisherAmerican Society of Mechanical Engineers (ASME)
ISBN (Electronic)9780791858981
StatePublished - 2019

Publication series

NameAmerican Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP
ISSN (Print)0277-027X

Bibliographical note

Publisher Copyright:
Copyright © 2019 ASME.


  • Finite element modeling
  • Friction welding
  • Heat exchanger
  • Tube-tubesheet

ASJC Scopus subject areas

  • Mechanical Engineering


Dive into the research topics of 'Finite element modeling of hybrid friction diffusion welding of tube-tubesheet joints'. Together they form a unique fingerprint.

Cite this