FRICTION WELDING

Friction Welding
Lesson Objectives
When you finish this lesson you will
understand:
Continuous Drive Friction Welding &
Applications
Variables Effecting Friction Welding
Variations of friction Welding Process
Dissimilar Materials Welded
Inertia Welding Process & Applications
Learning Activities
1. View Slides;
2. Read Notes,
3. Listen to lecture
4. Do on-line
workbook
5. View Video
Keywords: Friction Welding, Inertia Welding, Forging Pressure,
Orbital Friction Welding, Linear Friction Welding, Angular
Reciprocating Friction Welding, Radial Friction Welding, Friction
Stir Welding
Solid
State
Welding
Electrical
Chemical
Mechanical
Friction
Pressure &
Deformation
Friction
Weld
Friction welding is a
solid state joining
process that produces
coalescence by the heat
developed between two
surfaces by
mechanically induced
surface motion.
Definition of Friction Welding
Examine the Friction Weld Video on the Web Page
Continuous drive
Inertia
Categories of Friction Welding
One of the workpieces is
attached to a rotating
motor drive, the other is
fixed in an axial motion
system.
One workpiece is rotated
at constant speed by the
motor.
An axial or radial force is
applied.
Continuous Drive
Workpieces
Non-rotating vise
Motor
Chuck
Spindle
Hydraulic cylinder
Brake
Continuous Drive Friction
Welding
The work pieces are
brought together under
pressure for a predeter-
mined time, or until a
preset upset is reached.
Then the drive is
disengaged and a break
is applied to the rotating
work piece.
Continuous Drive
Workpieces
Non-rotating vise
Motor
Chuck
Spindle
Hydraulic cylinder
Brake
Continuous Drive Friction
Welding
Linnert, Welding Metallurgy,
AWS, 1994
Rotational speed
Heating pressure

Forging pressure

Heating time
Braking time
Forging time
Continuous Drive
Friction Welding Variables
(Continuous Drive)
AWS Welding Handbook
AWS Welding Handbook
AWS Welding Handbook
Equipment
Courtesy AWS handbook
Direct Drive Machine
Friction Welding Process Variations
AWS Welding Handbook
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
Tube
Rod to tube
Rod to plate
Tube to plate
Tube to disc
Continuous Drive
Friction Welding Joint Design
AWS Welding Handbook
Orbital Friction Welding
AWS Welding Handbook
Angular Reciprocating Friction Welding
AWS Welding Handbook
Linear Reciprocating Friction Welding
Radial Friction Welding
Used to join collars to shafts
and tubes.
Two tubes are clamped in
fixed position. The collar to
be joined is placed between
the tubes.
The collar is rotated
producing frictional heat.
Radial forces are applied to
compress the collar to
complete welding.
F
+
F
F
F
F
F
F
F
F
AWS Welding Handbook
Friction Surfacing
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 Stir Welding
Step -1
Step -2
Step -3
Step -4
clamping
force
Clamping
force
Friction Stir Welding
90
0
Corner welds
T-section ( 2- component top butt)
Friction Stir Welding
Fillet butt welds
Frequently competes with flash or
upset welding when one of the work
pieces to be joined has axial symmetry.
Used in automotive industry to
manufacture gears, engine valves, and
shock absorbers.
Used to join jet engine compressor
parts.
Continuous Drive
Friction Welding Applications
Friction Welded Automotive Halfshaft
Friction Welded Joint
Applications
Courtesy AWS handbook
Friction Welded Joints
Cross Section of Aluminum Automotive Airbag
Inflator. Three Welds Are Made Simultaneously
Camshaft Forging Friction
Welded To Timing Gear.
Applications
Courtesy AWS handbook
Friction Welded Joints
Inertia Welded Hand Tools
A Jet Engine Compressor Wheel
Fabricated by Friction Welding
Applications
Courtesy AWS handbook
Friction Welds
Aluminum to Steel Friction Weld
Dissimilar Metals Friction Welded
AWS Welding Handbook
Photomicrograph of Aluminum (top) to Steel (bottom)
AWS Welding Handbook
AWS Welding Handbook
Friction Weld Tantalum to Stainless Steel
Note: mechanical mixing
Continuous Drive Friction Weld of Titanium Pipe
Ti-6Al-4V-0.5Pd
246 mm
diameter

14mm wall
thickness

No shielding
used
Center HAZ
Froes, FH, et al, Non-Aerospace Applications of Titanium Feb 1998, TMS
Radial friction weld of Ti-6Al-4V-0.1Ru
Froes, FH, et al, Non-Aerospace Applications of Titanium Feb 1998, TMS
Properties in
Weld Better
than Base
Metal
Compressor
Combustor
Turbine
Fan
Linear Friction Weld
Repair of Fan Blades
Walker, H, et al, Method for Linear Friction Welding and Products
made by such Method US Patent 6,106,233 Aug 22, 2000
Friction Welding for
Mounting Ti Alloy
Rotor Blades
Shielding Gas &
Induction Pre-heat
Weld Nub
Linear Friction Weld
Force
Schneefeld, D,et al. Friction Welding Process for Mounting Blades of a Rotor for a Flow
Machine, US Patent 6,160,237 Dec 12, 2000
Friction Welding Connector to
Imbedded Window Wires
White, D et al, Friction Welding Non-
Metallics to Metallics, US Patent 5,897,964
Apr. 27, 1999
Silver Based
Ceramic Paint
Glass
Wire
Conductor
Friction Stir Welding Tool Design Modification
Metal Flow
Midling, O, et al, Friction Stir Welding US
Patent 5,813,592 Sep. 29, 1998
Hard Tool Tip Buried
in Work Piece
Force
Travel Speed
Friction Stir Welding Automation Moving Device
Elevation
Platform and
fixture device
Friction Stir
Welder
Mobile
Support
System
Ding, R. et al, Friction Stir Weld System for Welding and
Weld Repair, US Patent 6,173,880 Jan 16, 2001
Inertia Welding
One of the work pieces is
connected to a flywheel; the
other is clamped in a non-
rotating axial drive
The flywheel is accelerated to
the welding angular velocity.
The drive is disengaged and
the work pieces are brought
together.
Frictional heat is produced at
the interface. An axial force is
applied to complete welding.
Inertia Drive
Spindle
Workpieces
Non-rotating chuck
Hydraulic cylinder
Flywheel
Motor
Chuck
Inertia Welding Process
Description
Inertia Welding
C
IS
E
2

Where
E = Energy, ft-lb (J)
I = Moment of Inertia, lb-ft
2
(

kg-m
2
)
S = Speed, rpm
C = 5873 when the moment of inertia is in lb-ft
2

C = 182.4 when the moment of inertia is in kg-m
2

E
u
= Unit Energy, ft-lb/in
2
(J/mm
2
)
A = Faying Surface Area

A
E
E
u

Moment of inertia of the flywheel.
Initial flywheel speed.
Axial pressure.
Forging pressure.
Inertia Drive
Inertia Welding Variables
Linnert, Welding Metallurgy,
AWS, 1994
Equipment
Courtesy AWS handbook
Inertia Welding Machine
Linnert, Welding Metallurgy,
AWS, 1994
A
Few
Specific
Examples
Part Ave. Diameter
Range (in.)

Stator
components
10-80
Combustor
Casing
42 Waspaloy
Low pressure
turbine casing
72 Waspaloy
Other Parts various Inconel
Waspaloy
Hastelloy
Rene

Super-speed (750 SFM) Inertia Welding of Jet Turbine Components
Ablett, AM et al, Superspeed Inertia Welding, US Patenmt 6,138,896, Oct. 31, 2000
Problems
Melting Destroys Properties
Low (200F) Forging Temp Range Need Precise Control
Super-speed (750 SFM) Inertia Welding of Jet Turbine Components
Ablett, AM et al, Superspeed Inertia Welding, US Patenmt 6,138,896, Oct. 31, 2000
Control Parameters
Workpiece Geometry (size)
Applied Weld Load Contact Stress)
Initial Contact Speed (surface velocity
Unit Energy Input (moment of inertia,
radius of gyration)

D / SFM 12 RPM
A 5873 / RPM WK E
2 2

Where E = unit energy input

W = flywhel weight
K = radius of gyration
RPM = initial rotation
SFM = contact speed
D = diameter
A = contact area
Titanium Engine Valve
Titanium Aluminides
or
Titanium Borides
(Brittle at RT)
Titanium Alloy
(Ductile)
Inertia Weld
Jette, P , Sommer, A., Titanium Engine Valve, US Patent 5,517,956 May 21, 1996
Inertia Welding of
Magnesium and
Aluminum Wheels
for Motor Vehicles
Wheel
Spider
Inertia Weld
Aluminum Magnesium
Mg AM60 Mg AE42
Mg AM60 Mg AZ91
Mg AE42 Mg AZ91
Hot Inert Shielding Gas
Welding parameters
determined by the
lower-deforming alloy
or the alloy with higher
melting point
Separautzki, R,et al, Process for Manufacturing a Wheel for a Motor Vehicle
US Patent 6,152,351 Nov 28, 2000

In both methods, welding heat is developed
by frictional heat and plastic deformation.
Both methods use axial force for upsetting
purpose.
In both methods the axial pressure may be
changed (usually raised) at the end of
rotation.
Similarities between
Continuous Drive and
Inertia Drive
Continuous drive
One of the workpieces
directly connected to a
rotating motor drive.
Rotational speed remains
constant until the brake is
applied.
Rotational energy of the
workpiece dissipates
through friction and plastic
deformation, producing
welding heat.
Inertia drive
One of the workpieces is
connected to the flywheel.
Rotational speed decreases
continuously to zero during
the process.
Kinetic energy of the
flywheel dissipates through
friction and plastic
deformation producing heat.
Differences between Continuous Drive
and Inertia Drive