A Technical Seminar

On

FRICTION WELDING
PRESENTED BY,

SOURAV MONDAL
M.E-D-09/13
ROLL NO - 11800713074

BIRBHUM INSTITUTE OF ENGINEERING

& TECHNOLOGY

Contents
1. Introduction
2. Principle
3. Types of Friction Welding

4. Advantages
5. Disadvantages
6. Application

7. References

Introduction of Friction Welding

Friction welding is a group of solid state joining
process using heat generated through mechanical
friction between moving workpieces,with the
addition of an upsetting force to plastically
displace material.
Many dissimilar metal combination can be joined.
In conventional friction welding, relative rotation
between a pair of work pieces is caused is while
the work pieces are urged together.
Friction Welding is a type of forge welding, i.e.
welding done by the application of pressure.

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Principle

The principle of this process is the changing of mechanical

energy into heat energy. One component is gripped and rotated
about its axis while the other component to be welded to it is
gripped and does not rotate but can be moved axially to make
contact with the rotating component. At a point fusion
temperature is reached, then rotation is stopped and forging
pressure is applied. Then heat is generated due to friction and is
concentrated and localized at the interface, grain structure is
refined by hot work. Then welding is done, but there will not
occur the melting of parent metal.

1.One component
rotated rapidly, the
other is stationary

2.Rotating and
stationary components
brought together into
contact and force
applied
3. Axial force is
increased to bring
components into a
plastic state at
interface

4. Rotation is stopped and

more axial force is applied

5. Result - A full cross

sectional weld in the
complete metal.

Types of Friction Welding

Linear Friction Welding

Rotary Friction Welding
Inertia Friction Welding
Friction Stir Welding

Rotary Drive Friction Welding

The work pieces are
brought together under
pressure for a predetermined time, or until a
preset upset is reached.
Then the drive is
disengaged and a break
is applied to the rotating
work piece.

Workpieces
Motor

Spindle
Chuck
Brake

Non-rotating vise

Hydraulic cylinder

Inertia Welding Process

One of the work pieces is
connected to a flywheel; the
other is clamped in a nonrotating axial drive
The flywheel is accelerated to
the welding angular velocity.
Frictional heat is produced at
the interface. An axial force is
applied to complete welding.

Motor Flywheel

Spindle

Non-rotating chuck
Workpieces

Chuck Hydraulic cylinder

Friction Stir
Welding
Parts to be joined are
clamped firmly.
A rotating hardened steel
tool is driven into the joint
and traversed along the joint
line between the parts.
The rotating tool produces
friction with the parts,
generating enough heat and
deformation to weld the
parts together.

Butt welds

Overlap welds

Friction Surfacing

Friction Welding Joint Design

The joint face of at
least one of the
work piece must
have circular
symmetry (usually
the rotating part).
Typical joint
configurations
shown at right.

Rod

Rod to plate

Tube

Rod to tube

Tube to plate

Tube to disc

Advantage
1. Material and machining cost savings.
2. High production rates.
3. Similar and dissimilar material joined with no added fluxes
or filler metals.
4. Low distortion.

Disadvantage
1. Machine need sufficient power.
2. Angle of the job can not weld properly.
3. Heavy Force is required.

Friction Welding Applications

Used in commercial parts like bi-cycle
parts, medical equipment etc.
Used in automotive industry to
manufacture front wheel drive shaft
joints, wheels and rims.
Used in aerospace & agricultural field.

Friction Welded Joints

Friction Welded Joint

Friction Welded Automotive Halfshaft

References
Wikipedia.org
www.google.com

THANK YOU