Hybrid Friction Diffusion Bonding of Tube–Tubesheet Joint: A finite Element Model

A three-dimensional finite element model for hybrid friction diffusion bonding of tube–tubesheet joints is developed based on coupled Eulerian–Lagrangian technique. The investigation is aimed to study the effect of process parameters on temperature and pressure buildup in addition to material flow during the process. Temperature-dependent material properties were utilized in addition to Johnson–Cook material flow-stress model to describe the material behavior, while modified Coulomb’s frictional model was used to govern the contact between the tool and the workpiece. The numerical findings show good agreement with early experimental results. Lower tool rotational speed and longer welding time may lead to uniform tube deformation. Estimated temperatures and pressures could serve as key indicators for the diffusion bonding to take place or not.