2.7.

2 Inertia drive:

1. One of the work picces is connected to the flywheel

2 Rotational speed decreases continuously to zero during the process 3. Kinetic energy of
the flywheel dissipates through friction and plastic deformation producing heat

2.7.3 Inertia Welding Variables:

The variables in the Inertia Welding process are:

-Moment of inertia of the flywheel
-Initial flywheel speed.
-Axial pressure
-Forging pressure

2.8 FRICITION WELDING VARIABLES:

• The variables in the Friction welding process are

• Rotational speed

• Heating pressure

• Forging pressure

• Heating time

• Braking time

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2.9 QUALITY OF JOINTS:

High quality faction weld between various material joints (similar or dissimilar) can
be obtained within a certain range avial pressure and rotational speed

The quality of weld depends on

 Speed of rotation
 Friction pressure
 Type of material
• Diameter of work piece
• Forge pressure

2.10 ADVANTAGES OF FRICTION WELDING OVER OTHER METHOD:

The mam Advantages of Friction welding over other method arc

• Friction welding can produce high quality welds in a short cycle time
• No filler metal is required and flux is not used.
• The process is capable of welding most of the common metals It can also
be used to join many combinations of dissimilar metals Friction welding
requires relatively expensive apparatus Similar to a machine tool
• Easily automated
• High precision
• Consistent quality forge weld can be maintained and monitored
• Accurate controls over post weld tolerances
• metal to metal joints giving parent metal properties
• High production rates Material savings and reduced machining
• Low welding stress.

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• Low energy consumption
• Simplification of component design
• Dissimilar metal combinations Substitution of expensive materials with less costly
materials
• No process consumables, filler metal or protective gasses necessary Use of un skilled
labor
• Manual loading or automation optional Simple, clean mechanical operation
• All oxides and contaminants efficiently removed from weld face . Welding of un
equal cross sections.
• Surfaces preparation generally not necessary

• 2.11 TYPICAL APPLICATIONS OF FRICTION WELDING:

• Axles
• Flanges to Brushes
• Propeller shafts
• Axle Cases
• Flanges of Brushes
• Pump and Motor shafts
• Bosses to pulleys
• Forged products to bar or pipe
• Push rods
• Brake cams
• Front Wheel Drive Spindles
• Spindles
• Cam shafts
• Gear shift levers

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