Since the directly bonded interface between TiAl alloy and SCM440 includes lots of cracks and generated intermetallic compounds(IMCs) such as TiC, FeTi, and Fe2Ti, the interfacial strength can be significantly reduced. Therefore, in this study, Cu is selected as an insert metal to improve the lower tensile strength of the joint between TiAl alloy and SCM440 during friction welding. As a result, newly formed IMCs, such as Cu2TiAl, CuTiAl, and TiCu2, are found at the interface between TiAl alloy and Cu layer and the thickness of IMCs layers is found to vary with friction time. In addition, to determine the relationship between the thickness of the IMCs and the strength of the welded interfaces, a tensile test was performed using sub-size specimens obtained from the center to the peripheral region of the friction-welded interface. The results are discussed in terms of changes in the IMCs and the underlying deformation mechanism. Finally, it is found that the friction welding process needs to be idealized because IMCs generated between TiAl alloy and Cu act to not only increase the bonding strength but also form an easy path of fracture propagation.

With increasing use of SUH35/SUH3 dissimilar materials for automotive engine valves, it is required that stress singularities under residual stress on an interface for friction welded dissimilar materials analyzed to establish strength evaluation. The stress singularity index() and stress singularity factor( ) were calculated by using the results of stress analysis considering residual stress and loads. The stress singularities on variations for temperatures and loads acting from outside were analyzed and discussed. This paper suggested that the strength evaluation by using the stress singularity factors as fracture parameters, considering the stress singularity on an interface edge of friction welded dissimilar materials will be useful.

Friction welding of particulate reinforced aluminum composites was performed and the following conclusions were drawn from the study of interfacial bonding characteristics and the relationship between experimental parameters of friction welding and interfacial bond strength. Highest bonded joint efficiency (HBJE) approaching was obtained from the post-brake timing, indicating that the bonding strength of the joint is close to that of the base material. For the pre-brake timing, HBJE was . Most region of the bonded interface obtained from post-brake timing exhibited similar microstructure with the matrix or with very thin, fine-grained layer. This was attributed to the fact that the fine-grained layer forming at the bonding interface was drawn out circumferentially in this process. Joint efficiency of post-brake timing was always higher than that of pre-brake timing regardless of rotation speed employed. In order to guarantee the performance of friction welded joint similar to the efficiency of matrix, it is necessary to push out the fine-grained layer forming at the bonding interface circumferentially. As a result, microstructure of the bonded joint similar to that of the matrix with very thin, fine-grained layer can be obtained.

용접접합부 균열의 파괴역학적 해석을 위해서는 용접중에 발생하는 잔류응력해석과 파괴해석이 병행되어야 한다. 잔류응력이 존재하면 J-적분은 더 이상 적분경고에 관계없이 인정한 값을 갖는 특성을 잃어버리게 된다. 또한 균질한 재료와는 달리 이종재료 계면균열에서는 균열선난에서 Mode I과 Mode II의 파괴거동이 동시에 발생한다. 그러므로 이종강재 용접접합부 균열의 J-적분 해석을 위해서는 이종강재 용접시 발생하는 잔류응력이 존재하는 경우에도 적분경로에 관계없이 일정한 값을 갖는 새로운 J-적분식이 도입되어야 한다. 따라서 본 연구에서는 기존의 J-적분을 수정하여, 이종강재 용접시 발생하는 잔류응력이 존재하는 경우에 경로 독립성을 유지하는 J-적분을 고찰하고, 이를 이용하여 잔류응력과 외력이 동시에 작용하는 균열선단에서의 J-적분을 해석할 수 있는 프로그램을 개발하였다. 자체개발한 탄소성 해석프로그램을 이용하여 이종강재 용접시 잔류응력과 외력에 대한 응력분포를 계산하였으며, 이를 이용하여 잔류응력과 외력의 복합하중에 대한 J-적분을 계산하였다.

다양한 평면변형률 시편들의 균열선단 탄소성 응력상태들에 대한 경우, 여러 연구들을 동해, J-T접근방법의 유효 타당성이 충분히 검증되어졌다. 그러나 J-T 두 변수에 의한 균열선단 응력장 예측의 타당성을 보편화시키기 위해서는, 평면변형률 시편들과 같이 이상화된 구조가 아닌 실제적인 3차원 구조형상에 대한 연구가 필요하다. 이를 배경으로 본 연구에서는 평판과 직관에 대해 완전 3차원 유한요소해석을 수행하여 얻어진 응력장과 계산된 J-T두 변수로 예측되는 응력장을 비교함으로써, J-T 접근방법의 유효성 내지 한계성을 규명하였다.