Friction Welding

Contents
Introduction to welding
Friction welding
Types of friction Welding
Friction Stir Welding
  Introduction to Welding
 Welding: is a materials joining process in which two or
more parts are coalesced at their contacting surfaces by
a suitable application of heat and/or pressure.
Types of Welding
 generally welding have the following types
 Friction Welding
 Ultrasonic welding
 Diffusion welding
 Laser beam welding
 Electron beam welding
 Resistance welding
 Plasma arc welding
 Gas Tungsten arc welding(GTAW)
 Submerged arc welding(SAW)
 Electro gas welding(EGW)
 Flux cored arc welding(FCAW)
 Gas metal arc welding(GMAW)

Among those types we discusses

about friction welding .
 Friction Welding
 It is a solid-state joining process
 produces coalescence in materials, using
the heat developed between surfaces
through a combination of mechanically
induced rubbing motion and applied load.
 the heat required for welding is generated
through (as the name implies) friction at
the interface of the two components
being joined.
 During the welding process, surfaces are under
pressure and this period called the heating phase
continues until plastic forming temperature is
achieved.
 The temperature in the welding region for steels is
between 900 and 1300 oC. Heated metal at the
interface accumulates by increasing pressure after
heating phase.
 The friction is induced by mechanical rubbing
between the two surfaces, usually by rotation of one
part relative to the other, to raise the temperature at
the joint interface to the hot working range for the
metals involved.
 Then the parts are driven toward each other with
sufficient force to form a metallurgical bond.
 Types of friction welding

A. Continuous driven friction welding

B. Flywheel driven friction welding
C. Combination of the two
A. continuous driven friction
welding
 Mechanical energy is converted to heat by
applying pressure from rotating part to non-
rotating part.
 One of the parts is connected to the engine
inducement unit and rotates at a constant
velocity; a constant axial force is applied to
parts. Working parts interact with each
other during welding or until axial
shortening occurs. Then, braking system
stops the process.
B. Flywheel drive friction
welding
 flywheel induced system constantly
rotates and is joined to flywheel shaft
system to achieve a certain speed.
 After reaching a certain speed, engine
flywheel is separated from shaft flywheel.
Shaft flywheel having a low moment of
inertia stops without braking. Therefore,
this welding method is known as welding
of inertia .
C. Combination of the two
 This method is also sometimes termed as
flywheel induced friction welding. The
essential welding parameters are rpm,
friction force on the surface, the length of
friction time, and forging time on the
surface, forging time and time of brake.
 Friction Stir Welding

 It is a solid state welding process in which

a rotating tool is fed along the joint line
between two work pieces, generating
friction heat and mechanically stirring the
metal to form the weld seam.
 FSW is distinguished from conventional
FRW by the fact that friction heat is
generated by a separate wear-resistant
tool rather than by the parts themselves.
 The rotating tool is stepped, consisting of
a cylindrical shoulder and a smaller probe
projecting beneath it. During welding, the
shoulder rubs against the top surfaces of
the two parts, developing much of the
friction heat, while the probe generates
additional heat by mechanically mixing the
metal along the butt surfaces. The probe
has a geometry designed to facilitate the
mixing action.
Advantages
 Good mechanical properties of the weld
joint
 Avoidance of toxic fumes, warping, shielding
issues and other problems associated with
arc welding
 Little distortion or shrinkage
 good weld appearance.
Disadvantages
 An exit hole is produced when the tool is
withdrawn from the work, and
 Heavy-duty clamping of the parts is required.
Some examples of applications
of friction welding