The process requires no third party materials such as fillers, welding wire or gasses and is achieved by simply rotating one component part with a stationary component part. The resulting heat plasticizes the material which is upset or extruded from the faying surfaces, rotation is stopped and an axial forge pressure is applied to complete the process. The three key parameters of rotation, forge force and displacement are monitored throughout the weld cycle, resulting in a repeatable, robust and accurate finished component. Every weld is logged for total traceability.
Sample rotary geometries
Friction welding can accommodate a wide variety of geometries as seen below. The process is best suited to a simple butt joint weld prep. The interface needs to be clean and depending on accuracy/component requirements can either be saw cut square to the axis within 1% or machined. The weld face of both parts needs to be clean and clear of any contaminants, in particular, rust, scale, oxides etc as this can jeopardise weld quality.
Linear friction welding
This method uses oscillation instead of rotation and involves the rubbing together of two pieces of material while applying a load to produce frictional heat. The heating phase is rapid and efficient, producing a uniform heat affected zone. It ensures a very fast process, usually completed in a few seconds, with little or no joint preparation required. The result is a defect-free, solid state bond which achieves a 100% cross-sectional weld. No consumables or post weld treatment is required.