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Class - Friction Welding

Friction welding is a solid state welding process that produces welds through the compressive force and relative motion of workpieces. Heat is generated at the faying surfaces through friction, plasticizing the material. In friction welding, heat is generated at the interface by friction during rotation under pressure. The parts are then upset under increased pressure to complete the weld. There are two types: direct-drive welds parts through continuous rotation and pressure, while inertia-drive uses a flywheel to impart rotational energy and weld.

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Sriharsha Sarma
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33 views

Class - Friction Welding

Friction welding is a solid state welding process that produces welds through the compressive force and relative motion of workpieces. Heat is generated at the faying surfaces through friction, plasticizing the material. In friction welding, heat is generated at the interface by friction during rotation under pressure. The parts are then upset under increased pressure to complete the weld. There are two types: direct-drive welds parts through continuous rotation and pressure, while inertia-drive uses a flywheel to impart rotational energy and weld.

Uploaded by

Sriharsha Sarma
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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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.

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