Group Member

AITZAZ BUTTBSME 01103136

ARSLAN KHANBSME 01103144

SURKHAIL TARIQ

BSME 01103208

FAIZAN AMEERBSME 01103192

Friction Welding

DEFINATION;Friction welding (FW) is a class of solid-state welding processes that generates heat through mechanical friction between a moving work piece and a stationary component, with the addition of a lateral force called "upset" to plastically displace and fuse the materials. Technically, because no melt occurs, friction welding is not actually a welding process in the traditional sense, but a forging technique.

Basic Principal of FW

Continuous drive

Inertia

Categories of Friction Welding

One of the work pieces is attached to a rotating motor drive, the other is fixed in an axial motion system.

One work piece is rotated at constant speed by the motor.

An axial or radial force is applied.

Continuous Drive Friction Welding

The work pieces are brought together under pressure for a predator-mined time, or until a preset upset is reached.

Then the drive is disengaged and a break is applied to the rotating work piece.

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 Welding Process Description

Friction welding has become industry standard in a number of applications. Some of the

advantages of the process are detailed below • Weld monitoring can insure 100% weld quality • Friction welding produces a 100% cross

sectional weld area • Far superior weld integrity compared to MIG

welding • Limited operator training require – full

automation also possible

Advantages of Friction Welding

• The weld cycle is fully controlled by the machine • Repeatable results • Friction welding is a solid state process and does not suffer

from inclusions and gas porosity. • Friction welding required no consumables therefore

becomes more cost effective over time • Friction welding typically will complete a full cross

sectional weld in 15% of the time it take MIG welding to produce an 85% cross sectional

weld. • Friction welding requires no special weld interface

preparation welding) • No post machining is needed for friction welded

components in many cases • Dissimilar materials can be joined with no alloying of the

material

Due to the advantages of friction welding, it has now become industry standard in a

number of applications: • Trailer axles – welding spindle to the case.

Thompson Friction Welding are the only company to make a double ended

machine which can weld two spindles to the same housing simultaneously. Advantages

of this include o fast production time o extremely accurate weld .

Applications

o required machinery footprint reduction • Piston rods – welding the eye or yoke to the

shaft. Thompson Friction Welding has supplied many machines that can weld pre

chromed bars without any damage to the delicate chrome surface. • API drill pipes and drill rods – welding of

connectors to pipes and rods. Thompson Friction Welding are at the forefront

of technology advances in this area with new developments including internal

flash removal over undulating surfaces