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Friction
Mechanical
Friction Weld
Continuous Drive
Hydraulic cylinder
Continuous Drive
Spindle Chuck
Hydraulic cylinder
Brake
Continuous Drive
Rotational speed Heating pressure Forging pressure Heating time Braking time Forging time
Equipment
Inertia Welding
Inertia Drive
Spindle
Inertia Welding
IS E C
2
E Eu A
Where E = Energy, ft-lb (J) I = Moment of Inertia, lb-ft2 ( kg-m2) S = Speed, rpm C = 5873 when the moment of inertia is in lb-ft2 C = 182.4 when the moment of inertia is in kg-m2 Eu = Unit Energy, ft-lb/in2 (J/mm2) A = Faying Surface Area
Inertia Drive
Equipment
Titanium Alloy
(Ductile)
Jette, P , Sommer, A., Titanium Engine Valve, US Patent 5,517,956 May 21, 1996
Continuous drive
Inertia drive
One of the workpieces One of the workpieces is directly connected to a connected to the flywheel. rotating motor drive. Rotational speed decreases Rotational speed remains continuously to zero during constant until the brake is the process. applied. Kinetic energy of the Rotational energy of the flywheel dissipates through workpiece dissipates through friction and plastic friction and plastic deformation producing heat. deformation, producing welding heat.
Continuous Drive
Rod
Tube
Rod to tube
Rod to plate
Tube to plate
Tube to disc
Fan
Walker, H, et al, Method for Linear Friction Welding and Products made by such Method US Patent 6,106,233 Aug 22, 2000
Weld Nub
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
East Aurora, NY USA Moog and Thomson Friction Welding have developed the worlds largest linear friction welding machine. It is capable of welding a surface area of 10,000 mm2 (15 in2), nearly twice as much as previously achieved, and breaks the record of weld forge load at 100 tons.
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
Friction Surfacing
10 mm diameter mild steel consumable rods with 30 mm length. Mild steel Plates 10 mm thick were used as substrates.
Microstructural transformations during friction surfacing. (a) Consumable base material, (b) heat affected zone, (c) thermo-mechanically affected zone, (d) full recrystallized microstructure, (e) coating microstructure and (f) heat affected substrate. Process parameters: F = 5 kN; = 2500 rpm; v = 7.5 mm/s.
Continuous Drive
Applications
Applications
Cross Section of Aluminum Automotive Airbag Inflator. Three Welds Are Made Simultaneously
Applications
Friction Welds
Center
HAZ