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Friction Welding

Friction welding is a solid-state welding process that generates heat through mechanical friction between a rotating workpiece and a stationary component. It involves four stages: 1) loading the parts, 2) bringing one part up to rotational speed and applying axial force, 3) maintaining these conditions to reach desired temperatures, 4) stopping rotation and applying increased axial force to obtain fusion. There are two variations: direct drive, where one part is rotated by a motor, and inertia welding, where a flywheel initially rotates one part before contact. Friction welding allows joining of many metals, produces high quality welds quickly without filler metal, and is easily automated.

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Nallappan Rajj A
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217 views20 pages

Friction Welding

Friction welding is a solid-state welding process that generates heat through mechanical friction between a rotating workpiece and a stationary component. It involves four stages: 1) loading the parts, 2) bringing one part up to rotational speed and applying axial force, 3) maintaining these conditions to reach desired temperatures, 4) stopping rotation and applying increased axial force to obtain fusion. There are two variations: direct drive, where one part is rotated by a motor, and inertia welding, where a flywheel initially rotates one part before contact. Friction welding allows joining of many metals, produces high quality welds quickly without filler metal, and is easily automated.

Uploaded by

Nallappan Rajj A
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
Download as pptx, pdf, or txt
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FRICTION WELDING

Friction welding (FW) is a solid-state welding


processes that generates heat through mechanical
friction between a moving workpiece and a
stationary component, with the addition of a
lateral force called "upset" to plastically displace
and fuse the materials
The process can be described best in the four
stages :

I. Parts are loaded into welder, one in rotating


spindle and the other in a stationary clamp.
(Special tooling may be required if parts do not
have a natural axis of symmetry.)

II. Component in spindle is brought up to pre-


determined rotational speed and then a pre-
determined axial force is applied.

III. These conditions are maintained for a pre-


determined amount of time until desired
temperatures and material conditions exist.

IV. Rotational speed is then stopped and


increased axial force is applied until desired
upset is obtained. Components are then
unloaded and cycle is repeated.
Shape of fusion zone as function of Pressure and
Rotational Speed
FW Setup
Variations
There are two variations of the friction welding process

1. Direct Drive

2. Inertia welding
Direct Drive

 One part is held stationary and the other part is rotated by a motor
which maintains an essentially constant rotational speed

 The two parts are brought in contact under pressure for a specified
period of time with a specific pressure

 Rotating power is disengaged from the rotating piece and the


pressure is increased

 When the rotating piece stops the weld is completed

 This process can be accurately controlled when speed, pressure,


and time are closely regulated
Layout
Inertia welding

 Here a flywheel is revolved by a motor until a preset speed is


reached

 It, in turn, rotates one of the pieces to be welded

 The motor is disengaged from the flywheel and the other part to
be welded is brought in contact under pressure with the rotating
piece

 During the predetermined time during which the rotational speed


of the part is reduced, the flywheel is brought to an immediate
stop and additional pressure is provided to complete the weld
Layout
DIRECT Vs INERTIA
Factors involved in making a friction weld

• The rotational speed


which is related to the material to be welded and the diameter
of the weld at the interface.

• The pressure
Between the two parts to be welded. Pressure changes during
the weld sequence.

• The welding time


Time is related to the shape and the type of metal and the
surface area. It is normally a matter of a few seconds.
Weldable Materials
Advantageous
• Ability to produce high quality welds in a short cycle time

• No filler metal is required and flux is not used

• The process is capable of welding most of the common metals

• It can also be used to join many combinations of dissimilar metals

• The process is environmentally clean

• Narrow heat affected zones

• The process is easily automated for mass production

• Surface preparation/cleanliness is not significant with most materials


Limitations

• THE WELDING AREA OF AT LEAST ONE PART MUST BE


ROTATIONALLY SYMMETRICAL

• THIS PROCESS IS NORMALLY LIMITED TO MAKING FLAT AND


ANGULAR (OR CONICAL) BUTT JOINTS

• THE MATERIAL OF AT LEAST ONE COMPONENT MUST BE


PLASTICALLY DEFORMABLE UNDER THE GIVEN WELDING
CONDITIONS
Radial Friction Welding

USING COMPRESSION USING EXPANSION


Equipment

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