The rotary friction welding (RFW) is a robust, precise, productive and economical joining process that is used in many areas of mechanical engineering to produce lightweight structures consisting of combinations of ferrous and non-ferrous materials, for instance aluminium alloy and steel. Crucial for the design of such lightweight structures is the knowledge about the bonding strength. The bonding strength is the result of the bond formation depending on the present transient kinematic, kinetic and thermal states during the welding process being directly determined by the welding process parameters. Despite several years of empirical research, no reliable numerical modelling approach exists for the RFW process to analyse the bonding strength based on these transient state variables. For this reason, an improvement of the bond formation and therefore an increase in the bonding strength can only be tested experimentally. The main motivation of this paper is to develop an appropriate modelling approach for the estimation of the bonding strength for friction welded lightweight structures manufactured of an aluminium alloy and a structural steel. Therefore, a couple of aluminium alloy and steel welding experiments with different process parameters were performed and subsequently analysed concerning to the resulting bonding strength. Moreover, all the welding experiments were simulated in regard to the corresponding welding process in order to determine the present kinematic, kinetic and thermal state variables, like the strain rate, the stress and the temperature. Thus, a model for the characterization of the bond formation can be developed, which allows a correlation between the bond formation and the resulting bond strength based on the chosen welding process parameters. Finally, the model will be examined and discussed in terms of its plausibility and applicability.

旋转摩擦焊接 (RFW) 是一种坚固、精确、高效且经济的连接工艺，用于机械工程的许多领域，用于生产由黑色金属和有色金属材料（例如铝合金和钢）组合而成的轻质结构。对于此类轻质结构的设计至关重要的是关于粘合强度的知识。结合强度是结合形成的结果，取决于焊接过程中当前的瞬态运动学、动力学和热状态，由焊接工艺参数直接确定。尽管进行了多年的实证研究，但 RFW 工艺尚不存在可靠的数值建模方法来根据这些瞬态变量来分析粘合强度。因此，粘合形成的改善以及粘合强度的增加只能通过实验来测试。本文的主要动机是开发一种适当的建模方法来估计由铝合金和结构钢制造的摩擦焊接轻质结构的结合强度。因此，进行了一些具有不同工艺参数的铝合金和钢焊接实验，并随后分析了所得的结合强度。此外，所有焊接实验都针对相应的焊接过程进行了模拟，以确定当前的运动学、动力学和热状态变量，如应变率、应力和温度。因此，可以开发用于表征键合形成的模型，该模型允许基于所选焊接工艺参数在键合形成和所得键合强度之间建立相关性。最后，将对该模型的合理性和适用性进行检验和讨论。