Spatial and temporal evolution of temperature, hardness, and residual stress in linear friction welding of wrought and 3D-printed near-net blanks

• Established a linear relation between the workpiece burn-off rate and specific power input, eliminating the dependence on experimental data for modelling predictions. • Residual stress evolution during linear friction welding between the printed-to-printed and printed-to-conventional is modelled and validated for the first time in the literature. • Modelled the evolution of temperature, residual stress, and hardness over 150 process combinations, and validated the computed results with 31 meas