A finite element model of an elevated temperature upset welding process was developed to simulate the process and to study the role and sensitivity of the major process parameters. Particular attention was focused on the deformation characteristics by studying the displacement and stress fields generated for the purpose of obtaining a better understanding of this solidstate welding process. The paper describes the finite element formulation, the experiments used to validate the modeling, and a selected application for upset welding of a titanium alloy.

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