This study presents a finite element analysis (FEA) of internal stresses in welded tubes composed of alumina and mild steel, aiming to understand the mechanical behavior of these hybrid materials under various loading conditions. The welding process introduces complex stress distributions that can significantly affect the structural integrity and performance of welded joints. This research employs advanced FEA techniques to model the geometry and material properties of the alumina-mild steel tubes, allowing for a detailed examination of the internal stress profiles resulting from welding. The analysis focuses on identifying critical stress concentrations, evaluating the effects of temperature variations during welding, and assessing the overall structural response of the welded assembly. Results indicate that the interaction between the dissimilar materials leads to unique stress distributions, with implications for joint durability and failure mechanisms. This study provides valuable insights for engineers and designers in optimizing the welding process and enhancing the performance of alumina-mild steel hybrid structures in various industrial applications. The findings contribute to the growing body of knowledge on the behavior of welded composite materials, paving the way for improved design methodologies and material selections in engineering practice.

friction welding, intermetallic, FE model, interface, bending strength