Friction welding is solid-state joining technique that welds workpieces by

generating heat through mechanical friction.

In reality an apparently smooth surface consists of many microscopic projections, called

asperities. When one surface moves relative to another these asperities interact, see
Figure 1, generating friction – the force resisting motion between two or more interacting
surfaces. Interaction of these asperities through elastic and plastic yielding generates
heat. Friction welding utilises this phenomenon for joining applications. The induced
mechanical motion of friction welding generates heat, causing the materials to be joined
to soften and become viscous. While in the softened state, the mechanical motion of the
process mixes the materials to create a bond. The way by which the frictional heat and
material mixing occurs is very dependent on the friction welding process utilised, of
which there are four primary processes: Friction stir welding (FSW), friction stir spot
welding (FSSW), linear friction welding (LFW) and rotary friction welding (RFW).

Figure 1 – Asperity interaction

FSW and FSSW utilise a dedicated tool to generate the frictional heat and mechanical
mixing. FSW works by using a non-consumable tool, which is rotated and plunged into
the interface of two workpieces. The tool is then moved through the interface and the
frictional heat causes the material to heat and soften. The rotating tool then
mechanically mixes the softened material to produce a bond; see Figure 2(a). FSSW is
a variant of FSW and works by rotating, plunging and retracting a non-consumable tool
into two workpieces in a lap-joint configuration to make a “spot” weld. During FSSW
there is no traversing of the tool through the workpieces; see Figure 2(b).
LFW and RFW do not require a non-consumable tool, i.e. the individual workpieces to
be joined are used to generate the frictional heat and mechanical mixing. LFW works by
linearly oscillating one workpiece relative to another while under a compressive force.
The friction between the oscillating surfaces produces heat, causing the interface
material to soften and mechanically mix; see Figure 2(c). RFW is similar to LFW except
that the workpieces are often round and are rotated relative to each other; see Figure
2(d). During LFW and RFW the workpieces typically shorten (“burn-off”) in the direction
of the compressive force, forming the flash. During the burn-off interface contaminants,
such as oxides and foreign particles, are expelled into the flash. Once free from
contaminants, pure metal to metal mixing occurs, resulting in an integral bond. Although
the generated temperatures during friction welding are very hot, the material remains in
a solid-state condition (i.e. no melting occurs).

Figure 2 – A process schematic of: (a) FSW, (b) FSSW, (c) LFW and (d) RFW

Friction welding offers many advantages to the manufacturing sector, including:

 Remaining in the solid-state, therefore avoiding many of the defects associated

with fusion welding, such as pores and solidification cracks.
 Producing comparably low temperatures when compared to fusion welding,
which reduces intermetallic formation, allowing for a wide range of similar and
 dissimilar materials to be joined. The distortion of the welded component is also
reduced.
 Being able to join many ‘non-weldable’ aluminium alloys, namely from the 2xxx
and 7xxx series.
 Not requiring a filler metal, flux and shielding gas.
 Not requiring special edge preparation in most applications.
 Being easily automated, making the process highly repeatable and not
dependant on human influence, resulting in very low defect rates.
 Being able to produce welds with mechanical properties that are comparable or
superior to the parent material for a range of similar and dissimilar material
combinations.
 Being able to reduce the materials required to make a component by joining
smaller workpieces to produce a preform, which is subsequently machined to the
desired dimensions.