Abstract
Continuous drive friction welding process is widely used in various industrial applications to assemble shafts, tubes, and many other components. This paper's motivation was developing a CDFW model using the Finite Element Method (FEM). The coupling of the process's thermal and mechanical behaviors was considered during the simulation by COMSOL Multiphysics®. The construction of phase transition curves for Al6061 allowed determining several temperature-dependent thermophysical properties of the material. These properties are then injected in a second simulation to study the temperature evolution during welding. Subsequently, these results are compared and analyzed with the experimental outcomes. Excellent comparability between the model and experimental results was achieved. A unique phenomenon in the welding temperature profile was observed and explained through the model and experimental results interpretation.