A novel method to establish friction coefficient model for numerical simulation of inertia friction welding.

[Display omitted] • The angular velocity and interface temperature were simultaneously measured during the inertia friction welding. • The friction coefficient between Al alloy and steel was derived and related to the temperature, pressure, and sliding velocity. • The fiction coefficient model with linear fitting showed the best simplicity and very high accuracy and was successfully used in the simulation of temperature evolution. The precise friction coefficient at interface determines the friction behavior in inertia friction welding (IFW), its model is the basis to precisely describe the friction behavior in the numerical simulation of IFW. To measure the friction coefficient related to the temperature, pressure, and sliding velocity, the IFW trials between 2219-O Al alloy and 304 stainless steel were conducted with the simultaneous measurement of temperature and angular velocity evolutions. Two types of friction coefficient models were established by considering whether the effects of temperature and friction pressure were independent. The S-(T&P) L model, which considered the couple effect of temperature and friction pressure, was recommended as the best suitable model with its very high accuracy and best simplicity. The proposed model was successfully used in simulating the temperature evolution of IFW between Al alloy and steel tubes. The effect of the influencing variables on the friction coefficient was also discussed. [ABSTRACT FROM AUTHOR]