Friction welding is a solid-state welding process that joins two workpieces without melting them. It generates heat through mechanical friction caused by relative motion between the faying surfaces. This heat softens the surfaces, and an axial pressure is applied to merge the softened surfaces together. Friction welding produces high quality welds without using filler material. It is used in industries such as aerospace, automotive, and marine for components like tubes, shafts, gears, and valves. Benefits include joining dissimilar metals and producing welds with minimal waste.

1. Friction Welding
National Institute of Technology Durgapur
Seventh Semester Powerpoint Presentation
Advanced Welding Class Assessment 1
Under Dr. Arjyajyoti Goswami
Group 5
By 19ME8004,19ME8011,19ME8022,19ME8088,19ME8092,19ME8121,19ME8132
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2. What is Friction Welding?
● Friction welding is a solid state joining process that permanently joins
two workpieces by generating heat through mechanical friction.
● This mechanical friction is obtained due to the relative motion between
the two faying surfaces
● Friction welding produces high integrity full contact joints without the
use of any filler material, flux, or shielding gas.
● FW is classified as a solid state joining process because no actual
melting of the workpieces takes place in this process.
● Temperatures reached during this process are significantly lower than
the temperatures required to melt the materials, and the joint is made
when the faying surfaces soften due to the heat and are pressed
together.
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http://www.gatwicktechnologies.com/processes/friction-welding

3. Process Overview
● Workpieces made out of similar or
dissimilar materials are rubbed against
each other, which generates heat.
● Due to this generated heat, the rubbing
surfaces soften.
● An axial pressure is applied at the
interface which results in the softened
surfaces merging into each other and
forming a high quality joint.
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4. Friction Welding
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5. Application
Friction Welding usage
● For welding tubes and shafts.
● It is mostly used in aerospace, automobile, marine and oil
industries.
● Gears, axle tube, valves, drive line etc. components are friction
welded.
● It is used to replace forging or casting assembly.
● Hydraulic piston rod, truck rollers bushes etc. are join by friction
welding.
● Used in electrical industries for welding copper and aluminum
equipments.
● It's major application lies in Fabrication of Titanium alloy
integrated bladed disks.
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7. How does Friction Welding benefit the industry?
Friction Welding offers a wealth of solutions to tough
manufacturing problems.
● The process is consistent and repetitive, while also being
majorly machine controlled. This ensures compliance with
industry standards and independence from the skill of the
human operator.
● It allows for the permanent joining of two dissimilar
metals, for eg. aluminum to copper, copper to titanium,
stainless steel to aluminum - which is generally not
possible using other welding techniques. Thus it is utilised
in a host of industrial applications, as discussed further.
● FW results in high quality joints with less resource
consumption and waste generation, as no filler material is
involved. Hence post-weld machining requirements are
also considerably less.
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8. LINEAR FRICTION WELDING
1. Friction between oscillating surface
produces heat.
2. The heat causes the interface material to
plasticize.
3. Plasticized material is expelled from the
interface. This causes workpieces to shorten
(burn-off) in direction of compressive force.
This expels contaminants from faying
surface as well.
4. Once free from contaminants pure metal
to metal bond occurs resulting in a joint.
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9. MAJOR
APPLICATION
It's major application lies in Fabrication
of Titanium alloy integrated bladed
disks.
This is because LFW allows blade to be
integrally joined to disk.
Here fusion welding cannot be used
because it is not clean enough, and
causes defects.
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10. BENEFITS
1. Highly productive process.
2. Very little preparation required for
surfaces to be joined.
3. Impurities are removed.
4. Overcomes difficulties of fusion
welding processes.
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11. MICROSTRUCTURE
1. Weld Centre Zone
2. Thermomechanically affected
zone
3. Heat Affected Zone
4.Plastically Affected Zone
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12. ROTARY FRICTION WELDING(RFW)
Rotary friction welding (RFW) is a solid-
state joining process which works by
rotating one workpiece relative to
another while under a compressive axial
force.
The deformation process forms a flash
collar and causes the workpieces to
shorten in the direction of the
compressive force.
Can be Inertia Type or Flywheel Type.
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13. Inertia Type RFW Flywheel Type RFW
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14. Major Application
Turbine shafts, Automotive parts including steel
truck axles and casings, Monel-to-steel marine
fittings, Piston rods, Tubular transition joints
combining dissimilar metals (Aluminium-Titanium
and Aluminium-Stainless steel, for example)
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15. Microstructure in RFW
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16. Advantages
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.
4.Small heat affected zone when comparing the process to conventional flash welding.
5.Low levels of oxide films and surface impurities
6.No need to use gas, filler metal or flux. No slag that can cause weld imperfections.
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17. Disadvantage
1.Process limited to angular and flat butt welds.
2.Only used for smaller parts.
3.Hard to remove flash when working with high carbon steel.
4.It requires a heavy rigid machine in order to create high thrust pressure.
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18. Friction Welding VS Friction Stir Welding
Friction welding has its own shortcomings. This gave rise to the
need for something that follows the same principles as Friction
welding, but slightly more convenient.
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19. A new method called Friction Stir Welding was
formed.
Here, a rotating member is used to generate
friction between the 2 faying surfaces.
The heat from this friction is used to soften the
surfaces, and then permanently join them
together.
This rotating member can be made to move along
a desired path. This solves the problem faced by
friction welding over nonlinear joints.
The presence of an external member allows the
welding to happen without moving the actual
faying surfaces.
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20. Industrial applications
● Titanium alloy integrated bladed disks ~
LFW
● Friction welding is used in the fabrication
of tubes and shafts, naval, mining, and
automotive as well as in the aircraft
industries.
● It is 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.
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