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Friction Welding Machine
What Is Friction Welding?
Friction Welding is a completely mechanical solid phase process in which heat is generated by friction to produce a high integrity welded joint between similar or dissimilar metals. In this method, one component is rotated relative to, and in pressure contact, with the mating component to produce heat at the faying surfaces. The weld is completed by the application of a forge force during or after the cessation of relative motion.
In its simplest form, friction welding involves holding two components in axial alignment. Then rotate them under pressure causing the interface to heat up.
Why Friction Welding?
The advantages are both metallurgical and physical. A bonded joint is formed using no filler metal, flux or shield gas. The process is environmentally clean; no arcs, sparks, smoke or flames are generated by clean parts. Surface preparation/cleanliness is not significant with most materials since the process burns through and displaces surface impurities. During the friction welding process there are narrow heat affected zones.
The process is suitable for welding most engineering materials and is well suited for joining many dissimilar combinations. In most cases, the weld strength is as strong or stronger than the weaker of the two materials being joined. Operators are not required to have manual welding skills. Friction welding requires only simple integration into the manufacturing area. The process is easily automated for mass production. Welds are made rapidly compared to other welding processes. Plant requirements (space, power, special foundation etc.) are minimal for the friction welding process
Advantages of Friction Welding
Friction welding has been used by the automotive industry for decades in the manufacture of a range of components. The process is attractive for several reasons: The friction heating is generated locally, so there is no widespread softening of the assembly The weld is formed across the entire cross-sectional area of the interface in a single shot process The technique is capable of joining dissimilar materials The process is completed in a few seconds with very high reproducibility - an essential requirement for a mass production industry. Now, a new variant from the same stable of friction processes, known as ‘friction stir welding’, is finding increasing use in the fabrication of automotive components, even though its processing speed is not yet as rapid.