Solid state joining techniques are increasingly applied in a wide range of industrial applications. Friction welding is a solid state welding technique that is used to join similar or dissimilar materials. In this study, friction welding was applied to rotor shaft composed of a disk and a shaft. The disk and shaft were manufactured by hot forging and rolling, respectively. The aim of the study was to predict the structural characteristics during hot forging and friction welding process for rotor shaft of turbo charger. The structural characteristics were determined by heat input and heat affected zone (HAZ) during a short cycle time. Thus, transient FE analysis for hot forging and friction welding was based on heat transfer. The results were used to predict structural characteristics during hot forging and friction welding processes. The prototype of rotor shaft was manufactured by the result-based process parameters.
