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What is friction welding? Applications, Advantages and Disadvantages .

Friction welding is a solid-state welding method that produces heat by mechanical friction between work parts that are in relative motion with one another, with the inclusion of literal forces that aid in the joining of the component.
It is not fusion welding, but rather forge welding, so there is no melting of the material. The joint is formed as a result of the thermo-mechanical treatment of the surface that can be touched.
The workpieces are joined either relative to each other or by spinning to create friction and displace the material plastically on the surface in this form of welding. To complete the weld, extremely high pressure is needed.
It produces heat at the melting point of the workpiece, as previously said, to obtain when external pressure is applied to it. Friction occurs between the pieces before it becomes ceramic, which occurs at temperatures ranging from 900 to 1300 degrees Celsius for steel. At this stage, a continuously increasing friction force is applied to the work object, resulting in a permanent joint.

Friction Welding is applicable in the following:

  • Friction welding is used in the fabrication of tubes and shafts, naval, mining, and automotive as well as in the aircraft industries.
  • It is also useful in components that require friction weldings, such as gears, axle tubes, drivelines, and valves.
  • It is also used to link hydraulic piston rods, truck roller bushes, and so on. It is used to solder drill bits, connecting rods, gear levers, and other similar objects.
  • Finally, it is commonly used in the electrical industry to solder copper and aluminum equipment.

Advantages of Friction Welding

Friction Welding has many advantages, they are as follows
Friction welding is applicable in various fields and welds many things. Friction welding is of great benefit because it helps to lessen the grain formation of high heat and strengthen steel. It also does not melt the metal while welding. Friction welding is also used in aerospace, where lightweight metals like aluminum are used.
One benefit is that the weld surface is polished as a result of the motion between the products being combined, and maximum strength is achieved in the joint with no added weight to the workpiece.
Thermoplastics are also used for friction welding. It applies very little heat and friction to the components. This has shown that this method of welding can be used to connect metals to plastics using a machined metal interface.

  • Allows the joining of dissimilar materials that may otherwise be incompatible for welding using other joining processes.
  • Produces a small, heat-affected zone
  • There is no need for filler stuff.
  • Complete metal fusion is a consistent and repeated process.
  • Minimal Joint preparation
  • Faster turn-around times – in comparison to forgings, which usually have lead times of 6 months or more.
  • Increases product versatility significantly
  • Suitable for a wide range of amounts – from single prototypes to large-scale manufacturing

Disadvantages of Friction welding

One of the most significant drawbacks of friction welding is the constraint on workpiece dimensions. Since circular bars with identical cross-sections are limited, joint designs are limited, and work parts must be fixed.

  • Friction welding equipment is expensive.
  • Welding is not possible for materials that cannot be forged.

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What is friction welding? Applications, Advantages and Disadvantages .

by Piping Mart time to read: 2 min