FUTURE INSTITUTE OF ENGINEERING AND MANAGEMENT
CC-148/294
UNDER
MAKAUT, WB
PPT ON FRICTION WELDING
CONTINUOUS ASSSESSMENT#1
ADVANCED WELDING TECHNOLOGY
PE-ME702
PRESENTED BY
ASHISH SHARMA- 14800719031
MD.MODASSIR HUSSAIN- 14800719027
AYAAN SHAHAB- 14800719007
SUBHADEEP DATTA- 14800720012
DIPAYAN MANDAL-14800719024
PARTHIV DAS-14800719039
MECHANICAL ENGINEERING
7TH SEMESTER
AY: 2022-23
INTRODUCTION
Friction welding is solid-state joining technique that welds workpieces by generating heat through mechanical friction. In reality
an apparently smooth surface consists of many microscopic projections, called asperities. When one surface moves relative to
another these asperities interact, generating friction – the force resisting motion between two or more interacting surfaces.
Interaction of these asperities through elastic and plastic yielding generates heat. Friction welding utilises this phenomenon for
joining applications. The induced mechanical motion of friction welding generates heat, causing the materials to be joined to
soften and become viscous. While in the softened state, the mechanical motion of the process mixes the materials to create a
bond. The way by which the frictional heat and material mixing occurs is very dependent on the friction welding process utilised,
of which there are four primary processes: Friction stir welding (FSW), friction stir spot welding (FSSW), linear friction welding
(LFW) and rotary friction welding (RFW).
FSW and FSSW utilise a dedicated tool to generate the frictional heat and mechanical mixing. FSW works by using a
nonconsumable tool, which is rotated and plunged into the interface of two workpieces. The tool is then moved through the
interface and the frictional heat causes the material to heat and soften. The rotating tool then mechanically mixes the softened
material to produce a bond; see Figure 2(a). FSSW is a variant of FSW and works by rotating, plunging and retracting a non-
consumable tool into two workpieces in a lap-joint configuration to make a “spot” weld. During FSSW there is no traversing of the
tool through the workpieces; LFW and RFW do not require a non-consumable tool, i.e. the individual workpieces to be joined are
used to generate the frictional heat and mechanical mixing. LFW works by linearly oscillating one workpiece relative to another
while under a compressive force. The friction between the oscillating surfaces produces heat, causing the interface material to
soften and mechanically mix RFW is similar to LFW except that the workpieces are often round and are rotated relative to each
other During LFW and RFW the workpieces typically shorten (“burn-off”) in the direction of the compressive force, forming the
flash. During the burn-off interface contaminants, such as oxides and foreign particles, are expelled into the flash. Once free from
contaminants, pure metal to metal mixing occurs, resulting in an integral bond. Although the generated temperatures during
friction welding are very hot, the material remains in a solid-state condition (i.e. no melting occurs).
TYPE OF FRICTION WELDING-
Friction Welding Types
1>Inertia Friction Welding.
2>Direct Drive Friction Welding.
3>Linear Friction Welding.
4>Stir Welding (FSW) Friction
5>Orbital Friction Welding.
ADVANTAGE OF FRICTION WELDING
1>Can produce high-quality welds in short cycle time.
2>No filler metal is required and flux is not used.
3>The process is capable of welding most of the common metals. It can also be used to join many combinations of dissimilar
metals. Friction welding requires a relatively expensive apparatus similar to a machine tool. Easy to operate equipment Not
time-consuming
4>Low levels of oxide films and surface impurities
5>When compared to resistance butt welding creates better welds at a lower cost and higher speed, lower levels of electric
current are required
6>Small heat affected zone when comparing the process to conventional flash welding.
7>When compared to flash butt welding, less shortening of the component.
8>No need to use gas, filler metal or flux. No slag that can cause weld imperfections.
DISADVANTAGE OF FRICTION WELDING
1>Process limited to angular and flat butt welds.
2>Only used for smaller parts.
3>Complicated when used for tube welding.
4>Hard to remove flash when working with high carbon steel.
5>It requires a heavy rigid machine in order to create high thrust pressure.
BENEFITS OF OUR FRICTION WELDING PROCESS-
1> Enables joining of dissimilar materials normally not compatible for welding by other joining methods.
2> Creates narrow, heat-affected zone.
3> Consistent and repetitive process of complete metal fusion
4> Joint preparation is minimal – saw cut surface used most commonly
5> Faster Turn-around Times – compared to the long lead time of forgings, which are currently 6 months or longer.
6> Greatly increases design flexibility – choose appropriate material for each area of a blank Suitable for diverse quantities –
from single prototypes to high-volume production.
APPLICATION
Friction welding can be used to build better industrial rollers, tubes, and shafts. The process is often used to manufacture
these subassemblies for industrial printers, material handling equipment, as well as automotive, aerospace, marine, and oil
applications.
WORKING PRINCIPLE
Friction welding uses the principle of heat generation by friction between two members. During the friction welding process,
two surfaces to be welded are made to rub against each other at very high speed. The developed friction between the rotating
and non-rotating surface produces enough heat at the weld interface.
