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Mechanical Engineering

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Mechanical Engineering

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  1. What is Friction Welding? • Friction welding is a solid-state process (non-fusion) that is achieved through frictional heat • This heat is generated by controlled contact of two components until material reaches its plastic state, at which time plasticized material begins to form layers that intertwine with one another • The friction welding machine controls this contact through a series of unique parameters for rotational speed (rpm’s), axial force and time • Once these parameters are established, they are recorded, stored and then repeated with each cycle of the machine

  2. Types of friction welding • Inertia Stir • Friction welding

  3. Inertia Friction Welding In Inertia Welding, one of the work pieces is connected to a flywheel and the other is restrained from rotating. The flywheel is accelerated to a predetermined rotational speed, storing the required energy. The drive motor is disengaged and work pieces are forced together by the friction welding force

  4. Stir Friction Welding The frictional heating causes a softened zone of material to form around the probe. This softened material cannot escape as it is constrained by the tool shoulder. As the tool is traversed along the joint line, material is swept around the tool probe between the retreating side of the tool (where the local motion due to rotation opposes the forward motion) and the surrounding unreformed material

  5. Strong welds for all geometries • Narrowest heat affected zones • Short weld times save you time and money • There is no melting ,hence no solidification defects occur, gas porosity , and segregation • Easy to manage with only two quality control parameters - RPM and Pressure • Used for some alloys which are not fusion weldable like AL 7075 • Limitless panel length and width • Join dissimilar alloys Advantages of Friction Welding

  6. Worm holes • Oxide film due to Zn affecting surface tension of weld pool reduced diffusion • Cannot easily be used for making fillet welds Disadvantages

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