2 1Friction Welding

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FRICTION WELDING


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Friction Welding

Lesson ObjectivesWhen you finish this lesson you willunderstand: Continuous Drive Friction Welding &Applications Variables Effecting Friction Welding

Variations of friction Welding Process Dissimilar Materials Welded Inertia Welding Process & Applications

Learning Activities

1. View Slides;2. Read Notes,3. Listen to lecture4. Do on-line

workbook5. View Video

Keywords: Friction Welding, Inertia Welding, Forging Pressure,Orbital Friction Welding, Linear Friction Welding, AngularReciprocating Friction Welding, Radial Friction Welding, Friction

Stir Welding


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SolidState

Welding

Electrical

Chemical

Mechanical

Friction Pressure &DeformationFriction

Weld


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Friction welding is asolid state joining

process that producescoalescence by the heatdeveloped between twosurfaces by

mechanically inducedsurface motion.

Definition of Friction Welding


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Link to Friction Welding Video

Examine the Friction Weld Video on the Web Page
http://www-iwse.eng.ohio-state.edu/we601/friction%20weld%20video/we601%20friction%20weld%20video.aamhttp://www-iwse.eng.ohio-state.edu/we601/friction%20weld%20video/we601%20friction%20weld%20video.aam


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Continuous drive Inertia

Categories of Friction Welding


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One of the workpieces isattached to a rotating

motor drive, the other isfixed in an axial motionsystem.

One workpiece is rotatedat constant speed by themotor.

An axial or radial force is

applied.

Continuous Drive

Workpieces

Non-rotating viseMotor

Chuck

Spindle Hydraulic cylinder

Brake

Continuous Drive Friction

Welding


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The work pieces are brought together under

pressure for a predeter-mined time, or until a preset upset is reached.

Then the drive isdisengaged and a breakis applied to the rotatingwork piece.

Continuous Drive

Workpieces

Non-rotating viseMotor

Chuck

Spindle Hydraulic cylinder

Brake

Continuous Drive Friction

Welding


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Rotational speed

Heating pressure Forging pressure Heating time Braking time Forging time

Continuous Drive

Friction Welding Variables(Continuous Drive)


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Equipment

Courtesy AWS handbook

Direct Drive Machine


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Friction Welding Process Variations


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The joint face of atleast one of the

work piece musthave circularsymmetry (usually

the rotating part). Typical joint

configurations

shown at right.

Rod Tube Rod to tube

Rod to plate Tube to plate Tube to disc

Continuous Drive

Friction Welding Joint Design



Orbital Friction Welding



Angular Reciprocating Friction Welding



Linear Reciprocating Friction Welding


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Radial Friction Welding

Used to join collars to shaftsand tubes.

Two tubes are clamped in

fixed position. The collar to be joined is placed betweenthe tubes.

The collar is rotated producing frictional heat.

Radial forces are applied tocompress the collar to

complete welding.

F

+

FF F

FF

FF

F



Friction Surfacing


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Friction Stir Welding

Step -1

Step -2

Step -3

Step -4

clampingforce

Clampingforce


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900

Corner welds

T-section ( 2- component top butt)


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Fillet butt welds


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Friction Welded Automotive HalfshaftFriction Welded Joint

Applications


Friction Welded Joints


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Cross Section of Aluminum Automotive AirbagInflator. Three Welds Are Made Simultaneously

Camshaft Forging FrictionWelded To Timing Gear.

Applications


Friction Welded Joints


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Aluminum to Steel Friction Weld

Dissimilar Metals Friction Welded


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AWS Welding Handbook


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Photomicrograph of Aluminum (top) to Steel (bottom)



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Friction Weld Tantalum to Stainless Steel Note: mechanical mixing

Continuous Drive Friction Weld of Titanium Pipe


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Continuous Drive Friction Weld of Titanium Pipe

Ti-6Al-4V-0.5Pd246 mm

diameter

14mm wallthickness

No shieldingused

Center HAZ Froes, FH, et al, Non -Aerospace Applications of Titanium Feb 1998, TMS


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Radial friction weld of Ti-6Al-4V-0.1Ru

Froes, FH, et al, Non -Aerospace Applications of Titanium Feb 1998, TMS

Properties inWeld Better

than BaseMetal


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CompressorCombustor

TurbineFan

Linear Friction WeldRepair of Fan Blades

Walker, H, et al, Method for Linear Friction Welding and Productsmade by such Method US Patent 6,106,233 Aug 22, 2000

Friction Welding for


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Friction Welding forMounting Ti Alloy

Rotor BladesShielding Gas &

Induction Pre-heat

Weld Nub

Linear Friction Weld

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

ld


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Friction Welding Connector toImbedded Window Wires

White, D et al, Friction Welding Non -Metallics to Metallics, US Patent 5,897,964

Apr. 27, 1999

Silver BasedCeramic PaintGlass

WireConductor


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Friction Stir Welding Tool Design Modification

Metal Flow

Midling, O, et al, Friction Stir Welding USPatent 5,813,592 Sep. 29, 1998

Hard Tool Tip Buried

in Work Piece

Force

Travel Speed


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Friction Stir Welding Automation Moving Device

ElevationPlatform andfixture device

Friction StirWelder

MobileSupportSystem

Ding, R. et al, Friction Stir Weld System for Welding and

Weld Repair, US Patent 6,173,880 Jan 16, 2001


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I i D i


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One of the work pieces isconnected to a flywheel; theother 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 broughttogether.

Frictional heat is produced atthe interface. An axial force is

applied to complete welding.

Inertia Drive

Spindle

Workpieces

Non-rotating chuck

Hydraulic cylinder

FlywheelMotor

Chuck

Inertia Welding Process

Description


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Inertia Welding

CISE

2

Where

E = Energy, ft-lb (J)I = Moment of Inertia, lb-ft 2 ( kg-m 2)S = Speed, rpmC = 5873 when the moment of inertia is in lb-ft 2

C = 182.4 when the moment of inertia is in kg-m2

Eu = Unit Energy, ft-lb/in 2 (J/mm 2)A = Faying Surface Area

A

EE u

Inertia Drive


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Moment of inertia of the flywheel.

Initial flywheel speed. Axial pressure. Forging pressure.

Inertia Drive

Inertia Welding Variables


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Equipment


Inertia Welding Machine


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AFew

SpecificExamples


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Part Ave. DiameterRange (in.)

Statorcomponents

10-80

CombustorCasing

42 Waspaloy

Low pressureturbine casing

72 Waspaloy

Other Parts various InconelWaspaloyHastelloyRene

Super-speed (750 SFM) Inertia Welding of Jet Turbine Components

Ablett, AM et al, Superspeed Inertia Welding, US Patenmt 6,138,896, Oct. 31, 2000

Problems Melting Destroys Properties Low (200F) Forging Temp Range Need Precise Control


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Super-speed (750 SFM) Inertia Welding of Jet Turbine Components

Ablett, AM et al, Superspeed Inertia Welding, US Patenmt 6,138,896, Oct. 31, 2000

Control Parameters

Workpiece Geometry (size) Applied Weld Load Contact Stress) Initial Contact Speed (surface velocity Unit Energy Input (moment of inertia,radius of gyration)

D /SFM12RPM

A5873 /RPMWKE 22

Where E = unit energy inputW = flywhel weightK = radius of gyrationRPM = initial rotationSFM = contact speed

D = diameterA = contact area

Titanium Engine Valve


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Titanium Engine Valve

Titanium Aluminidesor

Titanium Borides(Brittle at RT)

Titanium Alloy(Ductile)

Inertia Weld

Jette, P , Sommer, A., Titanium Engine Valve, US Patent 5,517,956 May 21, 1996


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Inertia Welding ofMagnesium andAluminum Wheelsfor Motor Vehicles

Wheel Spider

Inertia Weld

Aluminum MagnesiumMg AM60 Mg AE42Mg AM60 Mg AZ91Mg AE42 Mg AZ91

Hot Inert Shielding Gas

Welding parametersdetermined by the

lower-deforming alloyor the alloy with higher

melting point Separautzki, R,et al, Process for Manufacturing a Wheel for a Motor VehicleUS Patent 6,152,351 Nov 28, 2000


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Continuous drive One of the workpieces

directly connected to arotating motor drive.

Rotational speed remainsconstant until the brake isapplied.

Rotational energy of theworkpiece dissipatesthrough friction and plasticdeformation, producingwelding heat.

Inertia drive One of the workpieces is

connected to the flywheel.

Rotational speed decreasescontinuously to zero duringthe process.

Kinetic energy of the

flywheel dissipates throughfriction and plasticdeformation producing heat.

Differences between Continuous Drive

and Inertia Drive

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2 1Friction Welding