Frictional welding

Frictional welding is a solid state welding process

1. Frictional Welding Group 13 150131A 150089B 150466E 150473X 150358B

2. What is frictional welding Solid state welding process Use relative motion and high force to create frictional heat at the weld face up to the points were plasticized After that intermixing at the welding face and end up with joint Actually it is not a welding process, a forging process . Processes are categorized by the types of relative motion

3. Different types of frictional welding processes Linear friction welding Rotary friction welding Stir friction welding Radial friction welding Orbiting friction welding

4. Linear Frictional welding process One piece at stationary and one piece is oscillating back and forth Stationary part would be pushed into the plate Use relative motion and high force in order to heat up the weld interface to the forging temperature creating a two piece forging Can use for complex geometry applications, in high volume applications, near net shape application example – jet engine blades, car frame

5. Linear Frictional welding process

6. Linear Frictional welding – slow motion

7. Rotary friction welding process One piece at stationary and second piece rotating Only one of the piece need to be in symmetric around its rotating axis. Next part does not necessary to be symmetric. Three main types Inertia friction welding Direct drive Hybrid

8. Rotary friction welding process

9. Stir frictional welding process Both work pieces are stationary Work pieces could be metal or extrusion Use non consumable pin tool that is rotating and providing the force for forging When the pin traverses along the seam it leaves a forged wake in it’s path Use to weld very thon material, weld long pieces Example – metal sheets

10. Stir frictional welding process

11. Radial frictional welding process Have a collar, that is rotating and compressing onto the outer diameter of a tube or a bar Orbital frictional welding process Orbiting the two parts around their centre axis

12. Advantages Simplicity of operation Less time required Low surface impurities and oxide films Compare to resistance butt welding produce improved welds Narrower heat affected zone. Heat affected area is small compared to the flash welding Strong weld for all geometries Can joint dissimilar materials

13. Disadvantages Process is restricted to flat and angular welds Use joining for small parts In case of tube welding process, get complicated In high carbon steel, it is difficult to remove flash Require heavy rigid machine due to high thrust pressure

14. Applications Automobile – Bimetallic engine valves, universal joint yoke Aerospace – turbine blade joining, seamless joining Consumer – hand tool Medical – stainless steel Marine - turbines Mining and drilling – twist drills Hydraulic equipment

15. References http://www.twi-global.com/technical-knowledge/published-papers/friction-and-forge-welding-processes-for-the-automotive-industry-september-1999/ http://www.mtiwelding.com

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