Comparative Finite Element Investigation of AISI 1005, AISI 1065, and a Hybrid Friction-Welded AISI 1005–1065 Bar under Tensile, Torsional, and Combined Loading

Abstract

We provide a detailed finite element analysis (FEA) focusing on the mechanical properties of low-carbon steel—AISI 1005; high-carbon steel—AISI 1065; and hybrid friction-welded specimens made from AISI 1005 and AISI 1065. In this study, we utilized SolidWorks Simulation to develop Our goal was to compare how unwelded and friction-welded configurations respond structurally, while also evaluating the feasibility of joining different carbon steels using this welding method. We defined the material properties based on standard steel grades and applied the same loading conditions across all models. The simulation results revealed that This investigation revealed that AISI 1065 steel boasts a higher tensile strength, while the friction-welded specimens show enhanced torsional resistance and a more effective load transfer through the weld interface. The hybrid specimen demonstrated a mechanical response that fell somewhere in between the parent materials, and it maintained its structural integrity regardless of the multiaxial loading conditions. The results obtained confirm that friction welding can indeed be used to create hybrid structural elements from both low- and high-carbon steels, showcasing the improved properties we've identified.