Flash Butt Welding

 Two pieces are brought together and the power supply is

switched on.
 Momentarily the two pieces are separated to create the arc
to melt the ends of the two pieces.
 Then the pieces are brought together and the power is
switched off while the two ends are fused under force.
 Most of the metal melted would flash out through the joint
and forms like a fin around the joint.
 Thermit Welding
 Thermit welding is a chemical welding operation.
 Heating and coalescence is achieved by superheated molten
metal produced from an exo-thermic chemical reaction
between a metal oxide and a metallic reducing agent.
 Usually iron oxide is used as a metal oxide and aluminum
or magnesium is used as metallic reducing agent.
 This mixture is also used for making bombs.
 Mixture: one part aluminum and three parts iron oxide and
ignited by a magnesium fuse.
8Al+ 3Fe3O4  9Fe + 4Al2O3 + 720 kcal
 Procedure
 Though this Thermit
process is Welding
used for joining, it has more in
common with casting than welding
(1)Steps
 Thermit ignited; (2) crucible tapped, superheated
in operation:
(1) Thermit
metal flowsignited
into mold; (3) metal solidifies to
(2) dCrucible
produce weldtapped,
ld j i t superheated metal flows into mold
joint
(3) Metal solidifies to produce weld joint
 Features of TW
 Weld surface is often smooth enough that no finishing is
required
 A temperature of over 2750 °C is produced in about 30
seconds, superheating the molten iron, which then flows
into a prepared joint, providing both heat and filler metal.
 Runners and risers must be provided, as in a casting, to
channel the molten metal and compensate for
solidification shrinkage.
 Copper, brass and bronze can be welded using a starting
mixture of copper oxide and aluminum.
 Nickel, chromium, and manganese oxides have also been
used in the thermit welding of the more exotic metals.
 Features of TW
 It can be used to join thick sections of material,
particularly in remote locations or where more
sophisticated welding equipment is not available.

 One such application is the field repair of the large steel

casting that are broken or cracked.
 Friction Welding
6

 Friction welding is a solid state welding process.

 Coalescence is achieved by frictional heat combined with
pressure.
 The heat required for welding in this process is obtained by the
friction between the rubbing surfaces of the parts to be joined.
 One of the parts to be joined is rotated at a high speed (about
3000 RPM), and the other part is axially aligned with the second
one and pressed tightly against it.
 The friction between the two parts raises the temperature of both
the ends to soften the ends (no melting).
 Then the rotation of the part is stopped abruptly and the pressure
on the fixed part is increased so that the joining takes place.
 Friction Welding
Friction Welding
Procedure
• •(1) Rotating part, no contact; (2) parts brought into contact to 
(1) Rotating part, no contact; (2) parts brought into contact to 
generate friction heat; (3) rotation stopped and axial pressure 
generate friction heat; (3) rotation stopped and axial pressure 
7
Friction Welding
applied; and (4) weld created
applied; and (4) weld created

• (1) Rotating part, no contact; (2) parts brought into contact to 
generate friction heat; (3) rotation stopped and axial pressure 
applied; and (4) weld created

Friction Welding
• (1) Rotating part, no contact; (2) parts brought into contact to 
generate friction heat; (3) rotation stopped and axial pressure 
(1) Rotating part, no contact
applied; and (4) weld created (2) Parts brought into contact to
generate friction heat

(3) Rotation stopped and axial pressure applied (4) Weld created
 Requirements for FW
8

 Friction welding machine is similar to a centre lathe.

 Power requirements: 25 kVA to 175 kVA.
 Machine requires a powered spindle to turn one part at high speed
and a means of applying an axial force between the rotating part
and the non-rotating part.
 Quick disengagement and the instantaneous braking of the
rotating part is necessary.
 Unfortunately, the process is restricted to joining round bars or
tubes of the same size, or connecting bars or tubes to flat surfaces
(joints where at least one of the pieces has circular symmetry).
 In addition, one of the components must be ductile when hot to
permit deformation during the forging stage.
 Features of FW
9

 Because virtually all of the energy is converted to heat, the

process is very efficient.
 Can be used to join a wide variety of metals or combinations
of metals including some metals, which are not normally
considered compatible, such as aluminum to steel.
 Since grain size is refined during the hot working, strength
of the weld is almost the same as the base metal.
 The axial compression force upsets the parts, and the
material displaced produces a flash.
 The flash must be subsequently trimmed to provide a
smooth surface in the weld region.
 No filler metal, flux, or shielding gases are required.
 With its short cycle times, the process is suitable for mass
 Process Parameters
10

 The major parameters are:

a) rotational speed
b) axial pressure
 The axial pressure depends on the strength and hardness
of the metals being joined.
 Pressures of 40 MPa for low-carbon steels to as high as
450 MPa for alloy steels are used.
 Materials Weldable using FW
This process can weld variety of metals which cannot be joined
by conventional processes.

 Aluminum  Aluminum Alloys

 Brass  Steel Alloys
 Cast iron  Magnesium
 Ceramic  Magnesium Alloys
 Copper  Tungsten
 Lead  Vanadium
 Bronze
 Advantages of FW
 Simplicity of operation and simple equipment
 Low power requirements
 Less time requirement
 Low surface impurities and oxide films
 Compared to resistance butt welding, FW produces
improved welds
 Process yields a narrow HAZ
 Less shortening of the component (reduction in part
lengths), as compared to that in flash or butt welding.
 There is no flux, gas, filler metal or slag present to cause
imperfections in welds.
 Disadvantages/Limitations
 Process is restricted to rods and tubes
 Tube welding process is complicated.
 Used only for joining small parts.
 Sometimes, quite a heavy flash is forced out
requiring post processing
 In case of high carbon steels, it is difficult to remove
flash.
 It requires heavy, rigid machine due to high thrust
requirement
 Applications
 For welding of various shafts and tubular parts of similar or
dissimilar metals.
 Automotive: Bimetallic engine valve, universal joint yoke, gear
hub etc.
 Aerospace: Turbine blade joining, seamless joining etc.
 Consumer: Hand tools, sports equipment
 Industrial: Spindles, tapers, tools
 Military
 Medical: Stainless steel joining of containers
 Marine: Shipping Industry
 Hydraulic equipment
 To coalesce medium-carbon steel shanks to carbide tips in
producing twist drills.