friction welding Process and its various application

Friction welding definition:

The friction welding process is the rotation of work piece induced sliding between rubbing surface and the produce coalescence of metal by heat obtained. It is a solid state welding process.

Step by step friction welding process                                    Step by step friction welding process

Some of friction welding equipment:

The friction welding process consist of one part is stationary and another one part rotated by using constant motor speed. The machine having rotational chuck and sliding chuck (not rotation). The work piece is holding on the rotation chuck.

The rotational chuck with work piece rotating in high speed and another work piece very close to revolving work piece and sufficient amount of force is applied so the friction is obtained with touch of work piece. When the friction is generated and that heat the work piece.

schematic diagram of friction welding
schematic diagram of friction welding

The coalescence is produced by heat, rotating power disengaged and increase the force. Now rotating work piece stop, the welding process completed. The speed, time, and force are controlled in accurately and closely regulated.

In this welding process the speed ranges of 75 to 105 meters per minute. Too high speed of rotation to give result in a wide HAZ. The low speed cannot be generated sufficient amount of heat and raise the temperature until require level.

The friction welding process will be requiring expensive apparatus on the machine tool.

To provide friction weld some important factor involved as follow.

  • The work piece rotational speed depends on work weld material and diameter of weld.
  • The pressure applied between the two weld parts. The pressure range will be changed. At the starting of weld it is very low and increased to create the frictional heat. When speed of rotation piece stopped and pressure suddenly after or before the rotation speed is stopped.
  • Weld timing:It is depends on weld material and require shape of weld and surface area of work piece. The part welded together in round cross sectional area.

friction welding Advantages:

  • High quality of weld with short time
  • No filler metal and flux not used
  • It can be weld part in dissimilar metal.
  • The most of common material can be welded in this process..

Some of friction welding disadvantages:

  • not applicable for thin metal
  • it is weld part only circular cross sectional area

The Industrial uses friction welding applications:

  1. The joint of dissimilar metal for example
  • Copper to steel
  • Copper to aluminum
  • Aluminum to steel or brass
  • Bronze to aluminum or steel

2. Plastic metal can be welded.

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