Rotary Friction Welding of Molybdenum without Upset Forging

A large instantaneous axial forging load is required to be applied for the final stage of rotary friction welding (RFW), which is usually conducive to obtaining clean, compact, and high-quality joints. However, for slender fuel claddings made of molybdenum (Mo) with low stiffness, the instantaneous axial forging load cannot be applied at the final stage of welding. This study carried out RFW tests without upset forging on Mo in the atmospheric environment and investigated the effects of welding time on joint morphology, axial shortening, microstructures, microhardness, tensile strength, and tensile fracture morphology. It found that the excessive and abrupt burning and a lot of smoke were generated around the weld zone during welding and spiral flashes were observed after welding. Under welding pressure of 80 MPa and spindle speed of 2000 r/min, the minimum average grain size and maximum tensile strength can be obtained in 4 s when the welding time is between 2-5 s. Scanning electron microscope (SEM) results show that there were morphologies of a large number of intergranular fractures and a small number of transgranular fractures in the fracture. The above results demonstrated that it is feasible to use RFW without upset forging to seal the last weld spot on upper end plugs of fuel claddings made of Mo in high-pressure inert gas, which would not only obtain reliable welding quality but also seal high-pressure inert gas in cladding tubes. The research results have a practical guiding significance of manufacturing accident-tolerant Mo nuclear fuel cladding.