Multi-Physics Modeling and Parameter Optimization for Flash Defect Control in Inertial Friction Welding of FGH98 Nickel-Based Powder Superalloy

Multi-Physics Modeling and Parameter Optimization for Flash Defect Control in Inertial Friction Welding of FGH98 Nickel-Based Powder Superalloy | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Multi-Physics Modeling and Parameter Optimization for Flash Defect Control in Inertial Friction Welding of FGH98 Nickel-Based Powder Superalloy Baiyuan Ou, Haoyang Chen, Ziwei Liu, Zhuo Xie, Mingxing Wang This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8518336/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 5 You are reading this latest preprint version Abstract The control of flash defects in inertial friction welding constitutes a critical challenge that limits the manufacturing accuracy of aero-engine hot-end components. This investigation employs FGH98 hollow cylinders as the subject of study, utilizing DEFORM-3D to develop a transient thermo-mechanical coupled numerical model. The research primarily explores the regulatory effects of rotational speed (800–1000 r/min) and upset pressure (2500–2900 PSI) on flash morphology defects. The results demonstrate that an overly high rotational speed (1000 r/min) causes the flash size to surpass the permissible engineering limits, machining. which not only results in material waste but also elevates the challenges associated with post-weld machining. Inadequate upset pressure (2500 PSI) leads to insufficient flash extrusion, thereby heightening the risk of incomplete bonding. Through multi-objective optimization, an optimal combination of process parameters was determined: a rotational speed of 900 r/min, an upset pressure of 2900 PSI, and a moment of inertia of 1150 lb·ft².With this parameter set, both the flash dimensions and the bend angle reside within the desirable range, and the joint strength achieves over 92% of the base metal's strength. This outcome provides key theoretical foundation and practical guidance for the manufacture of aero-engine hot-end components. Inertial Friction Welding FGH98 Nickel-Based Powder Superalloy DEFORM-3D Transient Simulation Flash Defect Control Process Parameter Optimization Full Text Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 09 Mar, 2026 Reviewers invited by journal 09 Mar, 2026 Editor invited by journal 15 Jan, 2026 Editor assigned by journal 09 Jan, 2026 First submitted to journal 07 Jan, 2026 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-8518336","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":603267488,"identity":"9fc8ca4b-104b-477f-83b4-1d91b8968552","order_by":0,"name":"Baiyuan Ou","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA7UlEQVRIiWNgGAWjYBACNvbG5gcfKmzk+NkbGx8kVNQw8Lf3GODVwsdz+JjhjDNpxpI9hw8bPDhzjEHizLkCvFrkJNISpHnbDiduuJGWJvmwhZnBICL/A36H8ZwxMJzZdphxw4Ecs4rEBjYGA4ncDQT80mPw4MO5dGbJA2fMbiTukCFCC8iWGWXWbHwHe4BazhBji0SOgTQPGzMPw2Ees4LENqBfgCIEtAC9z9PmLCFwjC2NAawlgpAWaCAbSPYwH5ZIOHOMR+LMGfxa5NshUVnfL/+w8eOPiho5glGJAXhIUz4KRsEoGAWjACsAACszUfO7gq/7AAAAAElFTkSuQmCC","orcid":"https://orcid.org/0009-0005-8873-2963","institution":"South China Agricultural University","correspondingAuthor":true,"prefix":"","firstName":"Baiyuan","middleName":"","lastName":"Ou","suffix":""},{"id":603267489,"identity":"2ef1b887-6f56-4598-a680-8e21bc43b441","order_by":1,"name":"Haoyang Chen","email":"","orcid":"","institution":"South China Agricultural University","correspondingAuthor":false,"prefix":"","firstName":"Haoyang","middleName":"","lastName":"Chen","suffix":""},{"id":603267490,"identity":"299d84f7-f69c-4965-bda0-c15240eb4ec7","order_by":2,"name":"Ziwei Liu","email":"","orcid":"","institution":"South China Agricultural University","correspondingAuthor":false,"prefix":"","firstName":"Ziwei","middleName":"","lastName":"Liu","suffix":""},{"id":603267491,"identity":"71b86d9a-4e26-4264-89fa-929be3030b37","order_by":3,"name":"Zhuo Xie","email":"","orcid":"","institution":"South China Agricultural University","correspondingAuthor":false,"prefix":"","firstName":"Zhuo","middleName":"","lastName":"Xie","suffix":""},{"id":603267492,"identity":"9f63258a-456f-463b-9792-9e55ce4759ab","order_by":4,"name":"Mingxing Wang","email":"","orcid":"","institution":"South China Agricultural University","correspondingAuthor":false,"prefix":"","firstName":"Mingxing","middleName":"","lastName":"Wang","suffix":""}],"badges":[],"createdAt":"2026-01-05 07:46:36","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-8518336/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-8518336/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":104509873,"identity":"db07bc9a-4a7b-452b-bc97-db8755e032d6","added_by":"auto","created_at":"2026-03-12 15:44:24","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1132118,"visible":true,"origin":"","legend":"","description":"","filename":"Weldingintheworld.pdf","url":"https://assets-eu.researchsquare.com/files/rs-8518336/v1_covered_fdc13e9d-7d67-42f9-ba11-59e0b0347a4a.pdf"}],"financialInterests":"","formattedTitle":"Multi-Physics Modeling and Parameter Optimization for Flash Defect Control in Inertial Friction Welding of FGH98 Nickel-Based Powder Superalloy","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"welding-in-the-world","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"witw","sideBox":"Learn more about [Welding in the World](https://www.springer.com/journal/40194)","snPcode":"40194","submissionUrl":"https://www.editorialmanager.com/witw/","title":"Welding in the World","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Inertial Friction Welding, FGH98 Nickel-Based Powder Superalloy, DEFORM-3D Transient Simulation, Flash Defect Control, Process Parameter Optimization","lastPublishedDoi":"10.21203/rs.3.rs-8518336/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-8518336/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThe control of flash defects in inertial friction welding constitutes a critical challenge that limits the manufacturing accuracy of aero-engine hot-end components. This investigation employs FGH98 hollow cylinders as the subject of study, utilizing DEFORM-3D to develop a transient thermo-mechanical coupled numerical model. The research primarily explores the regulatory effects of rotational speed (800\u0026ndash;1000 r/min) and upset pressure (2500\u0026ndash;2900 PSI) on flash morphology defects. The results demonstrate that an overly high rotational speed (1000 r/min) causes the flash size to surpass the permissible engineering limits, machining. which not only results in material waste but also elevates the challenges associated with post-weld machining. Inadequate upset pressure (2500 PSI) leads to insufficient flash extrusion, thereby heightening the risk of incomplete bonding. 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