Friction Welding - Introduction

 Friction Welding (FRW) is a solid state welding process which

produces welds due to the compressive force contact of work
pieces which are either rotating or moving relative to one another.

 Heat is produced due to the friction which displaces material

plastically from the faying surfaces.
Friction Welding - Introduction
 In friction welding the heat required to produce the joint is
generated by friction heating at the interface.

 The components to be joined are first prepared to have smooth,

square cut surfaces.
Friction Welding - Introduction
Basic steps involved in the friction
welding process:

 The parts to be joined are moved

relative to one another

 While under moderate pressure,

frictional heating occurs and softens
the material in the vicinity of the joint

 Then, an upsetting or forging pressure

is applied to complete the weld
Characterization of Microstructure at the interface of friction welding:
Types of FRW
Friction welding can be divided into two process, depending on the
manner by which rotational energy is converted into frictional heat.

1. Direct-drive or continuous-drive
2. Inertia-drive
1) Direct-Drive Friction Welding
1) Direct-Drive Friction Welding
 The spindle is first driven to a predetermined constant speed, and the two
parts are brought together under a preset axial force.

 Both rotation and force are maintained for a specific period, so that the
frictional heat will raise temperatures at the abutting surfaces enough to
render the material plastic and suitable for welding.

 The spindle is then disengaged from the driving unit, and a brake is
applied to bring the spindle to rest. At the same time, axial force either
remains unchanged or is raised to complete the weld.
1) Direct-Drive Friction Welding
Stages of direct – drive Friction Welding
Stage 1:
• One component is positioned in
a stationary clamp.
• The second part is positioned in
the rotating spindle, which is
then brought up to a pre-
defined rotational speed.
• At the right moment, pre-
defined axial force is applied.
1) Direct-Drive Friction Welding

Stage 2:

• These conditions are maintained

for a pre-determined amount of
time until the desired
temperatures and material
conditions exist.
• It's during this stage that the two
materials are plasticized
(becoming one).
1) Direct-Drive Friction Welding

Stage 3:
• Rotational speed is stopped.
• Then increased axial force is
applied until the desired upset
is obtained - completing the
weld.
• After joined part is unloaded
and next two parts are loaded,
the friction welding cycle
repeats.
1) Direct-Drive Friction Welding
Welding Parameter :

Three parameters control the character of a weld

1. Rotational speed
2. Duration of rotation
3. Axial force
2) Inertia-Drive Friction Welding
 Inertia welding is a modified form of friction welding, where the
rotating piece is attached to a rotating flywheel.

 The flywheel is brought to a specified rotational speed and is then

separated from the driving motor.

 The rotating assembly is then pressed against the stationary member

and the kinetic energy of the flywheel is converted into frictional heat.

 The speed of flywheel decreases as welding region heats up

 The weld is formed when the flywheel stops its motion and pieces
remains pressed together.
2) Inertia-Drive Friction Welding
Advantages:

 Since the conditions of the inertia welding are easily duplicated, welds
of consistent quality can be produced and the process can be easily
monitored

 The heat affected zone are usually narrow, since the time period is
usually short for heating and cooling

 More simple apparatus than continuous induced friction welding

Advantages of FRW
 No filler material, flux or shielding gas is needed

 It is an environment – friendly process without generation of smoke,

fumes or gases

 No material is melted so the process is in solid state with narrow heat

affected zone (HAZ)

 Oxides can be removed after welding process

 In most cases, the weld strength is stronger than the weaker of the two
materials being joined

 The process can be easily automated for mass production

 The process is very efficient and comparatively very rapid welds are made
Limitations of FRW
 The welding area of at least one part must be rotationally symmetrical,

 This process is normally limited to making flat and conical butt joints.

 Atleast the material of one component must be plastically deformable

under the given welding conditions.