Continuous Drive Rotary Friction Welding

i
ROTARY FRICTION WELDING
FOR
SIMILAR / DISSIMILAR METALS & PLASTIC
By:
Usman Ali
2014-uet-ccet-mech-05
M. Ahmad
Hafiz Zahid Ali
Qamar Abbas
Supervisor:
Engr. ABU BAKAR DAWOOD
June 2018
Department of Mechanical Engineering
Chenab College of Engineering &Technology
Gujranwala
Affiliated with
University of Engineering & Technology, Lahore

ii
DEDICATION
To our loving parents and teachers who enabled us
to come up the challenges with their blended love,
affection and guidance from the cradle of
childhood.
Specifically dedicated to
(Sallallaho Alaihi Waalihi Wasallam)

iii
Certificate
This is to certify that we have examined that thesis and
have found that it is completed and satisfactory and
fulfills the requirements of B.Sc. in Mechanical
Engineering
__________________
Engr. ABU BAKAR DAWOOD
(PROJECT ADVISOR)
Department of Mechanical Engineering
Chenab College of Engineering &Technology
Gujranwala
JUNE 2018

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Certificate
This is to certify that the following students are the project team.
USMAN ALI
2014-UET-CCET-MECH-05 sig._________________
M. AHMAD
2014-UET-CCET-MECH-09 sig._________________
HAFIZ ZAHID ALI
2014-UET-CCET-MECH-14 sig._________________
QAMAR ABBAS
2014-UET-CCET-MECH-15 sig._________________
APPROVED BY: ________________ __________________
PROJECT ADVISOR HOD MECHANICAL

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Acknowledgement
In the name of Allah, the Most Gracious, the Most Merciful.
Man gets whatever he strives for. And this path of intellect and research cannot be
travelled alone. It requires a continuous struggle and support from teachers, friends and
family. I’m lucky enough to have a lot of people supporting me throughout this struggle.
First of all, my gratitude and my respect to my Bachelor’s FYP supervisor Prof. Abu Bakar
Dawood, for this unparalleled support and guidance throughout this project. He has been very
kind person and I’m really grateful for his inspiration and confidence in me.
PROJECT TEAM

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Abstract
The process of welding is being extensively used in the industry and nowadays Friction welding
is of great importance because it doesn’t use filler materials and the joint obtained, has
excellent properties.
This research is about the use of a new property for the strength estimation in modeling of
Rotary Friction Welding Process. Previously the mathematical models that have been
developed used the techniques of constant friction and slip-stick friction.
The process of welding is being extensively used in the industry and nowadays Friction welding
is of great importance because it doesn’t use filler materials and the joint obtained, has
excellent properties. In Friction welding a number of scientists have worked on obtaining the
temperature plot of the welding joint. Comparisons are made in between the experimental
values and the model plots. The purpose behind this project is to join the similar, dissimilar and
plastics by rotary friction welding process. We use Mild Steel, Aluminum and Stainless Steel as
similar metal’s welding. In case of dissimilar metals, I weld Stainless Steel and Mild Steel. And
the new work of this project is the welding of thermoplastics. We weld PPR (polypropylene
random copolymer) and PPRC together as a friction welding of similar plastics and study the
strength of joint.

Table of Content
CHAPTER 1 - WELDING..................................................................1
1.1 INTRODUCTION.......................................................................2
1.2 TYPES OF WELDING .................................................................2
1.2.1 PRESSURE WELDING .............................................................2
1.2.2 HEAT WELDING ...................................................................2
1.2.3 FRICTION WELDING...............................................................2
CHAPTER 2 - FRICTION WELDING ....................................................3
2.1 DEFINITION..........................................................................3
2.2 TYPES OF FRICTION WELDING..................................................4
2.2.1 LINEAR FRICTION WELDING ...................................................4
2.2.2 ROTARY FRICTION WELDING .................................................4
2.2.3 ORBITAL FRICTION WELDING................................................4
2.3 ROTATIONAL FRICTIONAL WELDING TYPES.................................5
2.3.1 INERTIAL ...........................................................................5
2.3.2 DRIVE...............................................................................5
2.4 STAGES OF FRICTION WELDING...............................................5
2.5 HAZ STRUCTURE AND JOINING MECHANISIM..................6
2.6 ZONE IN FRICTION WELDING ...................................................7
2.6.1 CONTACT ZONE ..................................................................7
2.6.2 FULLY PLASTICIZED ZONE ....................................................7
2.6.3 PARTLY DEFORMED ZONE .....................................................7
2.6.4 UN-DEFORMED ZONE.........................................................7
CHAPTER 3 – THEORETICAL BACKGROUND OF ROTARY FRICTION
WELDING....................................................................................8

3.1 BACKGROUND ........................................................................8
3.2 ADVANTAGES OF FRICTION WELDING .........................................9
3.3 DISADVANTAGES OF FRICTION WELDING ....................................9
3.4 APPLICATION ......................................................................10
CHAPTER 4 – EXPERIMENTAL SETUP ..............................................11
4.1 PARTS OF EXPERIMENTAL SETUP..............................................11
4.2 LATHE ..............................................................................12
4.3 PNEUMATIC JACK................................................................13
4.4 REGULATOR VALVE .............................................................13
4.4.1 SINGLE STAGE REGULATOR .................................................15
4.4.2 DOUBLE STAGE REGULATOR ...............................................16
4.5 AIR COMPRESSOR ...............................................................16
4.6 PENUMATICE PIPE...............................................................17
4.7 DRILL CHUCK........................................................................18
4.8 PRESSURE GAUGE ...............................................................18
4.9 METHODLOGY....................................................................19
CHAPTER 5 EXPERIMENTATION....................................................20
5.1 FRICTION PARAMETERS..........................................................20
5.1.1 RPM PARAMETERS.............................................................21
5.1.2 PRESSURE PARAMETER .......................................................21
5.1.3 RADIUS PARAMETER ..........................................................22
5.2 SIMILAR METALS ..................................................................22
5.2.1 MILD STEEL......................................................................23
5.2.2 STAINLESS STEEL 304........................................................24
5.2.3 ALUMINUM……. .........................................................25

5.3 DISSIMILAR METALS........................................................26
5.3.1 MILD STEEL WITH STAINLESS STEEL ...................................26
5.4 PLASTICS……….... ..........................................................27
5.4.1 PPR-C…………. ..........................................................27
5.5 PPR-C PIPE WELDED SAMPLES...........................................28
5.6 SPECIFICATION OF PLASTICS...............................................30
5.7 PPR-C PIPE WITH SOCKET WELDING.....................................30
5.8 RESULTS …………….........................................................31
5.8.1 EFFECT OF RPM ON STRENGTH........................................32
5.8.2 EFFECT OF FRICTION PRESSURE ON STRENGTH ......................33
5.8.3 EFFECT OF UPSET PRESSURE ON STRENGTH.........................34
5.8.4 EFFECT OF DIAMETER ON STRENGTH..................................35
5.9 DISCUSION AND CONCLUSION…………......................................36
6 REFRENCES…………..................................................................37

LIST OF TABLE
TABLE TITLE PAGE NO.
TABLE 1 MILD STEEL…………………………………………………………………23
TABLE 2 PARAMETERS OF STAINLESSSTEEL……………………………………..24
TABLE 3 PARAMETERS OF ALUMINIUM………………………………………….25
TABLE 4 PARAMETERS OF STAINLESS STEEL…………………………………….26
TABLE 5 PARAMETERS OF PPRC………………………………………………… 27
TABLE 6 SPECIFICATION OF PPRC……………………………………………….30
TABLE 7 INCREASSING OF RPM ………………………………………………….32
TABLE 8 INCREASSING THE FRICTION PRESSURE……………………………….33
TABLE 9 INCREASSING THE UPSET PRESSURE……………………………..……34
TABLE 10 INCREASSING THE DIAMETER…………………………………………35

LIST OF FIGURE
FIGURE LABEL PAGE NO.
FIG. 1 HISTORY OF WELDING…………………………………………………1
FIG. 2 TYPES OF WELDING…………………………………………………….2
FIG. 3 INTERFACIAL CONDITION OF FRICTION WELDING………………..3
FIG. 4 TYPES OF GENERAL FRICTION WELDING……………………………4
FIG. 5 STAGES OF FRICTION WELDING PROCESS………………………….6
FIG. 6 APPLICATION OF FRICTION WELDING………………………………10
FIG. 7 BLOCK DIAGRAM OF EPERIMENTAL SETUP………………………..11
FIG. 8 FRICTION WELDING MACHINE……………………………………….12
FIG. 9 PNEUMATIC JACK ……………………………………………….……13
FIG. 10 PRESSURE REGULATOR VALVE…………………………………….14
FIG. 11 SINGLE STAGE REGULATOR ……………………………………….15
FIG. 12 DOUBLE STAGE REGULATOR ………………………………………16
FIG. 13 AIR COMPRESSOR ……………………………………………………17
FIG. 14 PNEUMATIC PIPE ……………………………………………………..17
FIG. 15 DRILL CHUCK …………………………………………………………..18
FIG. 16 PRESSURE GAUGE…………………………………………………….19
FIG. 17 VARIATION OF WELDING PARAMETERS WITH TIME ………….. 20
FIG. 18 MILD STEEL WITH MID STEEL………………………………………. 23
FIG. 19 STAINLESS STEEL WITH STAINLESS STEEL…………………………24
FIG. 20 ALUMINIUM WITH ALUMINIUM ……………………………………25
FIG. 21 MILD STEEL WITH STAINLESS STEEL ………………………………26

FIG. 22 PPRC WITH PPRC………………………………………………….27
FIG. 23 WELDED PIPES UNDER DIFFERENT FRICTION PRESSURE………28
FIG. 24 WELDED PIPES UNDER DIFFERENT FORGED PRESSURE………29
FIG. 25 WELDED PIPES WITH DIFFERENT RPM…………………………29
FIG. 26 WELD OF PIPE WITH SOCKET …………………………………….30
FIG. 27 BREAKING OF JOINT UNDER TENSILE LOAD …………………….31
FIG. 28 BREAKING OF JOINT UNDER TENSILE LOADING ………………..31

Rotary Friction Welding 1
Chapter 1
1.Welding
1.1 Introduction
Welding is the process of fabrication that joins materials .the materials usually metals
and plastics. Different types of welding is used for fusion of materials by using heat
generated.
Welding technique is known to humans since 1000 BC and it was a main thing to join
metals for making weapons such as swords and shield.
With the advent of technology the process improved to the generation of heat by
using electricity. This heat was then used to melt the metal for its fusion. Electric
welding process is believed to be used in 1782 in Germany. However majority of the
references point to late nineteenth century for the development of electric arc welding
process.
A brief history of welding process is shown in the figure below.
Figure 1. History of Welding

1.2 Types of welding
The welding technology has following types
1.2.1 Pressure Welding
Pressure welding is the type of welding in which welded joint is produced by applying
external pressure.
1.2.2 Heat Welding
In this type of welding heat is used to weld metals each other.
1.2.3 Friction welding
This is the purest form of welding in which heat generated by friction force to weld
similar and composite metals The subcategories of these three types are below
Figure 2. Types of Welding

Chapter 2
2 Friction Welding
2.1 Definition
According to American Society Friction welding is a solid state joining process that
produces coalescence of materials under compressive force contact of work piece
rotating or moving relative to one another to produce heat plastically displace
material from the faying surface. Under normal conditions, the faying surfaces do not
melt. Filler metal, flux, and shielding gas are not required with this process’. The heat
generated by these friction metal pieces on both sides of the interface and this
molten metal initiates the welding procedure. The pressure on the static metal piece
is increased to reach the fusing temperature, and once when enough temperature is
reached the rotation of the piece is stopped and the static piece is forced with a high
pressure to fuse and strengthen the weld.
The main apparatus needed for this type of welding is basically a machine (lathe
type) that rotates one piece at certain speed and the other static piece with a
hydraulic assembly is pushed against that rotating part to produce friction and create
weld bond.
Fig 1 shows the illustration of whole friction welding process.
Figure 3. Illustration of interfacial conditions during friction welding
(a) Dry Friction; (b) Plastic Flow

2.2 Types of friction welding
There are following types of friction welding
1. Linear friction welding
2. Rotary friction welding
3. Orbital friction welding
These three processes are shown in the figure 2 shown below. Rotary friction
welding is the oldest and most used process because of the simplicity of the used
apparatus in all processes which mentioned above.
Figure 4. Types of General Friction Welding
2.2.1 Linear Friction Welding
In this process the relative motion of two pieces produced under pressure in small
and fixed amplitude parallel to each other to create welded joint
2.2.2 Rotary friction welding
Rotary friction welding is the simplest welding process in this process rotary friction
created between to parts which we want to weld.
2.2.3 Orbital welding
In Orbital friction welding the motion between two part produced around their
longitudinal axis at constant speed.

2.3 Rotational friction welding types
The Rotational Friction welding is further divided into two main categories, depending
upon the drive of the rotational part.
 Inertia Drive
 Continuous/Direct Drive
2.3.1 Inertia drive
It uses the stored kinetic energy in the flywheel to rotate one of the work pieces.
2.3.2 Continuous or Direct drive
It uses the continuous source of rotation to be converted into the heat. It uses motor
to drive it.
2.4 Stages of Friction Welding Process
There are 3 stages in Friction Welding process.
The first stage is also called the heating stage. At this stage two pieces work with a
relative The motion between them is combined under axial pressure. Temperature in
Increased interface due to friction and applied pressure, this reduces the flow
Emphasis on materials.
 In the next stage, the material is unable to withstand user pressure and
temperature, and it deforms plastically the production of flashes. These
flashes are important in strength.
 Welding joints Since these flashes remove the contamination of slag and
oxides from the facade.
 In the third case or the case of the application, the rotation stops and the two
pieces of work are retained.
 High compressive strength, this leads to high strength welding joints.

Figure 5. Stages of Friction Welding Process
2.5 HAZ structure and joining mechanism
Diffusion is the main phenomenon in friction welding when the measured interface
temperature and extrapolated temperature were measured along With metallographic
studies
Different researchers can demonstrate the existence of layers at the interface of the
spread especially when joining dissimilar metals[6]. Joint strength for dissimilar
metals increases as the solubility of both metals increases as a result a high strength
bond is made in between the dissimilar metals.
It’s is an established fact that diffusion doesn’t only increases the quality of the joint.
It may deteriorate the joint as well. For example the joint in the joining of carbon steel
or medium plain carbon steel, becomes ductile due to decarburization at the weld
joint.

Similarly, Steel and aluminum, copper and titanium, joint naturally brittle due to
formation of the metallic phase with each other. When dissimilar properties of this
type of joint Study co-thin layers, was found on both sides of the interface of Welding
metal.
2.6 Zone in friction welding
2.6.1 Contact zone
The friction occurs or where the zone with metal fragments Transferred from screen
to screen. If you turn in this zone the main parameter is the rotational velocity that
control of strain rate of zone. This is the zone that undergoes severe plastic
deformation, severe straining and the re-crystallization of the grain structures, this
results in the formation of highly fine grain structure.
2.6.2 Fully Plasticized zone
In this zone grains does not participate in friction and rubbing. However, plastic
deformations in itself a considerable amount of it. Grains In this zone are quite
smooth and regularly changing due to Re-crystallization and high Temperature.
2.6.3 Partly deformed zone
We go with the contact zone as a move from full plastic zone Encountered by
partially deformed zone temperature is relatively low as well, and strain rate. These
factors are poor and Re-crystal microstructure coarser.
2.6.4 Un-Deformed Zone
The material in this phase doesn’t undergo phase transformation, depending on the
maximum temperature. This results in the formation of the grains in this region.

Chapter 3
3 Rotary Friction Welding
3.1 Background
Rotary friction welding is the process of joining of a solid-state that has been using for
development for many years.
This is also known as spine welding technique, it involves one part that is fastened
together at high speeds and pressed to the other to be attached, which is installed in
a fixed position. This friction in result cause warms the parts to a high temperature. At
this temperature they can join together, the spin force this removed at this point and
while cooling the two parts are pushed together.
Its use is generally limited to circular parts or cylindrical, rotary friction welding is an
excellent option for joining dissimilar materials.
It has many other benefits: it is fast, inexpensive, involves the use of any
consumables, and can accommodate operational monitoring to ensure quality.
Because of its solid nature, it allows the cutters to join the properties close to those in
the mother material
Rotary friction welding has been widely used across industry, and has been used for
many applications. These include the following:
 Copper and aluminium electrical connections
 Transition joints between aluminium alloys and stainless steels
 Automotive parts including steel truck axels and casings
 Monel-to-steel marine fittings
 Turbine shafts
 Aluminium alloys to titanium for military applications
 Titanium alloys for aerospace components
 Cuttings tools
 Piston rods

3.2 Advantages of friction welding
Large kinds of materials can be joined by using Friction welding. It can also be used
to join many combinations of dissimilar metals in addition to similar metals[3].
We can connect a large variety of materials using friction welding. It can also be used
to join many unmatched metal combinations as well as similar metals
Another advantage of friction welding is that in this process the mechanical energy is
converted directly into the thermal energy resulting in a significant temperature
gradient. This large temperature gradient results in a very small heat-affected area
(HAZ). Due to the reduction of HAZ, the deformation of the embedded metals is very
small.
This process is highly efficient in energy use and leads to a short period of adhesion,
resulting in high productivity. This welding process is defined as a solid-state welding
process, which means that the defects associated with the other porous i-e welding
process and slag contamination in melting and hardening are not observed in this
process
Another advantage of this process is that during burning and forging at high
pressure, the removal of the slag contamination in the façade leads to higher welding
strength points. Linking non-identical metals is the main advantage of this process
and can lead to full joint strength if the correct parameters are selected for this
process. This force is the result of the formation of a completely new material in the
common interface of the original minerals.
Friction welding produces a tight weld with 100% interface. This eliminates the risk of
defects associated with conventional welding operations, for example. Slots, leakage
and porosity.
Friction welding does not require fillers or gas for flow or flow. This leads to a
minimum cost of this process
For this process, there is no need for joint preparation. Commonly used joints are
made by saw cut work pieces. This is because, the formation of plastic material at the
interface eliminates any need of joint preparation.
The process has short cycle times. This leads to the possibility of automating this
process and thus lowering the labor cost of the process. This process does not use
any flow or greenhouse gases and does not produce any dangerous fumes or fumes.
This makes the process environmentally friendly. This process is not at all serious for
operators compared to conventional welding.
3.3 Disadvantages
It is concluded that the method rotary friction welding is the simplest method. But it
has an limitation, i-e it cannot be used for the welding of non-circular cross section
parts.

The non-uniform thickness of heat affected zone (HAZ) is another main disadvantage
of rotary friction welding. It is because of the generation of non-uniform heat
generation rate at the interface because of the linear change in rotational speed over
the radial distance from the center.
3.4 Application of friction welding
Friction welding is used in very large range of industries like automotive,
petroleum,electrical industries, aerospace, and agriculture. It is being used in wide
range of application of butt joints in shaft to engine valves and complicated jet engine
parts.
Friction Welding is being used in wide range of industries including automotive,
agriculture, petroleum, aerospace and electrical industries. It has a wide range of
application from butt joints in shaft to engine valves and complicated jet engine parts.
Figure 6. Application of friction welding

Chapter 4
4 Experimental setup
4.1 Parts of experimental setup
The parts of experimental setup are following
 Lathe
 Pneumatic jack
 Regulator valve
 Air compressor
 Pipes
 Drill chuck
 Pressure gauge
Figure 7. Block Diagram Of Experimental Setup

Figure 8. Friction Welding Machine
4.2 Lathe Machine
A lathe machine is a machine in which using special tools for removing metals from
work piece to achieve a desired size and shape. It is very useful machine to operate
various metals removing operations like facing, turning, knurling, chamfering,
grooving, taper turning etc. for using special tools. It is also called mother of
machines.
The engine lathe is an accurate and versatile machine on which many operations can
be performed. These operations are:
 Bed
It is horizontal beam that holds the swarfs and chips.
 Headstock
It contains the high precision bearings which hold the horizontal axle.It is also known
as the spindle.
 Spindle
It is a hollow horizontal axle with internal and external threads on the inboard by
which the woodworking pieces can be mounted on. It is rotating axis of the machine.
 Tailstock
It is the counterpart of the headstock. It is non-rotating part of machine that can slide
in and out directly in line with headstock spindle parallel to the axis of the bed.

 Carriage
This is composed of a saddle and an apron and is used as a mount to the cross-
slide.
 Cross-slide
This is a flat piece that sits crosswise on the bed which can be cranked at right
angles with the bed.
 Tool Post
It is top on the cross-slide and holds the cutting tool in place.
4.3 Pneumatic jack
Pneumatic jacks used compressed air to transfer forces for the purpose of pushing
or moving heavy machinery or material, lifting. With the help of compressed air
Pneumatic power turns electric power into mechanical power.
Figure 9. Pneumatic jack (1.0 MPa)
Different types of pneumatic tools are used in different aspects of the construction
industry from jackhammers to jacking systems. In Pneumatic systems mostly air used
as a fluid medium because air is economical ,safe and easily available.
In trenchless technology such as jacks, pipe ramming are used for the purpose of
lifting bulky pipes, positioning them for installation and jacking them forward during
the installation process.
4.4 Regulator valve
Regulator is pressure control valve that increase and decrease the fluid pressure to a
desired value .only used for liquids and gases and also used two or more devices
with same output pressure setting.
Operation:

A pressure control valve called regulator major function is to pass the fluid for
maintaining constant output pressure.
If we need decreases the fluid flow, then the regulator must decreases the fluid flow
as well. If we want increases the fluid flow, then the regulator must increases the fluid
flow and provide a constant output pressure at the end.
Figure 10. Pressure Regulator Valve
A regulator has three main components includes a restricting component, a loading
component, and a measuring component.
The restricting component is a part that can restrict to the flow of fluid such as a
poppet valve,globe valve,butterfly valve.
 The loading component is a part that can apply the required force to the
restricting component. That loading can be given by a spring,a
weight,the diaphragm actuator, a piston actuator.
 The measuring component is used to determine when the inlet flow is equal to
the outlet flow. The diaphragm itself is often used as a measuring element; it
can serve as a combined element.
In the below figure single stage regulator, a force balance is used on the diaphragm
to control a poppet valve in order to regulate pressure. With no inlet pressure, the
spring above the diaphragm pushes it down on the poppet valve, holding it open.
Once inlet pressure is introduced, the open poppet allows flow to the diaphragm and
pressure in the upper chamber increases, until the diaphragm is pushed upward
against the spring, causing the poppet to reduce flow, finally stopping further
increase of pressure. By adjusting the top screw, the downward pressure on the
diaphragm can be increased, requiring more pressure in the upper chamber to
maintain equilibrium. In this way, the outlet pressure of the regulator is controlled.
4.4.1 Single stage regulator
High pressure gas from the supply enters into the regulator through the inlet valve.
The gas then enters the body of the regulator, which is controlled by the needle

valve. The pressure rises, which pushes the diaphragm, closing the inlet valve to
which it is attached, and preventing any more gas from entering the regulator.
Figure 11. Single stage regulator
The outlet side is fitted with a pressure gauge. As gas is drawn from the outlet side,
the pressure inside the regulator body falls. The diaphragm is pushed back by the
spring and the valve opens, letting more gas in from the supply until equilibrium is
reached between the outlet pressure and the spring. The outlet pressure therefore
depends on the spring force, which can be adjusted by means of an adjustment
handle or knob.
The outlet pressure and the inlet pressure hold the diaphragm/poppet assembly in
the closed position against the force of the large spring. If the supply pressure falls, it
is as if the large spring compression is increased allowing more gas and higher
pressure to build in the outlet chamber until an equilibrium pressure is reached. Thus,
if the supply pressure falls, the outlet pressure will increase, provided the outlet
pressure remains below the falling supply pressure. This is the cause of end-of-tank
dump where the supply is provided by a pressurized gas tank. With a single stage
regulator, when the supply tank gets low, the lower inlet pressure causes the outlet
pressure to climb. If the spring compression is not adjusted to compensate, the
poppet can remain open and allow the tank to rapidly dump its remaining contents. In
other words, the lower the supply pressure, the lower the pressure differential the
regulator can achieve for a given spring setting.

4.4.2 Double stage regulator
Figure 12. Double stage regulator
.
Two stage regulators are two single stage regulators in one that operate to reduce
the pressure progressively in two stages instead of one. The first stage, which is
preset, reduces the pressure of the supply gas to an intermediate stage; gas at that
pressure passes into the second stage. The gas now emerges at a pressure (working
pressure) set by the pressure adjusting control knob attached to the diaphragm. Two
stage regulators have two safety valves, so that if there is any excess pressure there
will be no explosion. A major objection to the single stage regulator is the need for
frequent torque adjustment. If the supply pressure falls, the outlet pressure increases,
necessitating torque adjustment. In the two stage regulator, there is automatic
compensation for any drop in the supply pressure. Single stage regulators may be
used with pipe lines and cylinders. Two stage regulators are used with cylinders and
manifolds.
4.5 Air compressor
An air compressor is a device to compress the air using gasoline or diesel engine or
electric motor and stored pressurize air in tank. The kinetic energy of air stored in the
tank. When the tank fill with compress air, then the compressor shut off. High
pressurized air stored in the tank. When pressurized air utilized for particular work
then pressure of tank reaches its lower limit, then turn on the air compressor again
and store more pressurized air.

Figure 13. Air Compressor
Air compressor is different from air pump. Air pump inject air from one context
(surrounding environment) and pressurized air extract from other end. Air pumps
have no pressurized air storage tank. Air compressor is much expensive and difficult
to operate as compared to air pumps
4.6 Pneumatic Pipes
We use pipes for flow of compressed air through air compressor towards pneumatic
jack.
Figure 14. Pneumatic Pipes

4.7 Drill Chuck
A drill chuck is a specialized self-centering, three-jaw chuck, usually with
capacity of 0.5 in (13 mm) or less and rarely greater than 1 in (25 mm), used to
hold drill bits or other rotary tools. This type of chuck is used on tools ranging from
professional equipment to inexpensive hand and power drills for domestic use; it is
the type a person who does not normally work with machine tools is most likely to be
familiar with.
Figure 15. Drill Chuck
Some high-precision chucks use ball thrust bearings to reduce friction in the closing
mechanism and maximize drilling torque. One brand name for this type of chuck,
which is often generalized in colloquial use although not in catalogs, is Super Chuck.
A pin chuck is a specialized chuck designed to hold small drills (less than 1 mm
(0.039 in) in diameter) that could not be held securely in a normal drill chuck. The drill
is inserted into the pin chuck and tightened; the pin chuck has a shaft which is then
inserted into the larger drill chuck to hold the drill securely. Pin chucks are also used
with high-speed rotary tools other than drills, such as die grinders and jig grinders.
4.8 Pressure gauge
Pressure measurement is the analysis of an applied force by a fluid (liquid or gas)
on a surface. Pressure is typically measured in units of force per unit of surface area.
Many techniques have been developed for the measurement of pressure
and vacuum. Instruments used to measure and display pressure in an integral unit
are called pressure gauge or vacuum gauge . A manometer is a good example as it
uses a column of liquid to both measure and indicate pressure. Likewise the widely
used Bourdon gauge is a mechanical device which both measures and indicates and
is probably the best known type of gauge.

A vacuum gauge is a pressure gauge used to measure pressures lower than the
ambient atmospheric pressure, which is set as the zero point, in negative values
(e.g.: -15 psi or -760 mmHg equals total vacuum). Most gauges measure pressure
relative to atmospheric pressure as the zero point, so this form of reading is simply
referred to as "gauge pressure". However, anything greater than total vacuum is
technically a form of pressure. For very accurate readings, especially at very low
pressures, a gauge that uses total vacuum as the zero point may be used, giving
pressure readings in an absolute scale.
Figure16. Pressure gauge
Other methods of pressure measurement involve sensors which can transmit the
pressure reading to a remote indicator or control system.
4.9 Methodology
Continuous drive friction welding performed on lathe machine. One job is hold in
lathe chuck and other job is hold in special fixture of drill chuck which fix with
pneumatic jack rod. The lathe chuck job is moving job in circular pattern while other
job is still. When job starts rotating friction produced between there jobs pressure
applied on still job through pneumatic jack. After this jobs starts melting a layer of
melting jobs material producesd on it and apply break to chuck and pressure applied
and weld joint occurs.
 All experiment carried out for 10mm diameter
 Maximum RPM we use 1400
 Friction time and forge time measure with the help of stopwatch.
 Forge pressure shown by pressure gauge

Chapter 5
5 Experimentation
5.1 Friction Parameters
The most important thing is the selection of friction welding parameters while joining
dissimilar metals.
In this process the one part is rotated at certain speed and other part is held
stationary, and with specific force stationary part is pushed axially till the plastic
deformation and then the rotation stops and the part is held under high pressure until
the joint cools down.
The following graph shows the different parameters influencing the friction welding.
Figure17. Variation of Welding parameters with time in direct drive friction welding

Variation of Welding parameters with time in direct drive friction welding
It is evident from the graph that the main parameters to be controlled in Rotary
friction
Welding are the welding time, rotational speed and axial forces . These variables
determine the heat energy that is introduced into the weld joint. This is shown in the
graph above.
According to the above graph the process can be divided into 3 stages. Initially the
pressure of increases rapidly to a high value as the process starts. It then decreases
to the equilibrium value after some time. This rapid rise and then decrease in the
pressure is due to the formation and then the breaking of interfering asperities and
then the softening of the material in the plastic phase. During the second phase the
friction torque somewhat remains constant. And the third phase is associated with the
forging. The rotation stops. The axial forces are increased and this creates the
forging effect. Due to increased axial forces the friction torque also increases and
reaches a maximum value before it rapidly decreases to zero.
The heat supplied to the metal, doesn’t increase the temperature when the phase
change occurs, but is used to change the molecular form.
Friction welding is being a multi-physics phenomenon. It cannot be expressed just as
a model of a single physical process. For this purpose the modules of heat transfer
in solids and solid mechanics were used.
In Solid Mechanics the pair of contact was defined as a frictional contact with a static
frictional co-efficient of 0.61 between Aluminum and steel.
Heat Transfer in Solids determines the Pair Thermal Contact uses the following
equation as used by Ahmet Can[12] for the calculation of heat flux.
𝒒=𝝅.𝝎.𝑷.𝒓 (W/m2)
The P is the pressure being applied, 𝛚 is the rotational speed of work piece and r is
the radius of the work piece in this equation.
5.1.1 Rpm parameter
According to formula the heat flux is directly proportional to the rpm of the spinning
job. If the rotating part rotates with more rpm then the heat flux increased.
5.1.2 Pressure parameter
Heat flux directly proportional to the pressure applied on the job which we want to be
weld. If pressure changes then the heat flux automatically changes.

5.1.3 Radius parameter
Heat flux and radius of the job are directly proportional. If radius is large then heat
flux produces more because of area relatively increased.
 Similar Metal
1. Mild steel
2. Stainless steel
3. Aluminum
 Dissimilar Metals
1. Mild steel to Stainless steel
 Plastics
1. PPR-C pipe
5.2 Similar Metals
In similar metals we weld common materials which are standardized and are in
industrial use. We weld Steel with steel Aluminum with Aluminum Stainless steel with
Stainless Steel and Platics with Plastics. Further u can see the parameters of
different materials during continuous drive friction welding.

5.2.1 Mild Steel
Name Value Description
t1 18 sec Friction Time
P1 20 Psi Friction Pressure
t2 12 sec Forge Pressure
P2 38 Psi Forging Pressure
Rad 10mm Radius of the rods
Length 150mm Length of Steel rod
w 1660 RPM
Table 1. Parameters for Mild Steel
Figure18. Mild Steel with Mild Steel

5.2.2 Stainless Steel 304
w 1660 RPM
Table 2. Parameters for Stainless Steel
Figure 19. Stainless Steel with Stainless Steel

5.2.3 Aluminum
w 1660 RPM
Table 3. Parameters for Aluminum
Figure 20. Aluminum with Aluminum

5.3 Dissimilar Metals
5.3.1 Mild Steel with Stainless Steel
w 1660 RPM
Table 4. Parameters for Mild Steel with Stainless Steel
Figure21. Mild Steel with Stainless Steel

5.4 Plastics
5.4.1 PPR-C
w 1660 RPM
Table 5. Parameters for PPR-C
Figure 22. PPR-C with PPR-C

5.5 PPR-C pipe Welded Samples
Figure 23 (a). Welded 32mm dia pipes under different friction Pressure
Figure 23 (b). Welded pipes under different friction Pressure

Figure24. Welded pipes under different forged Pressure
Figure 25. Welded pipes with varying RPM

5.6 Specifications
property Value Unit
Density 909 g/cm3
Tensile strength 25 Mpa
Elongation rate 600 %
Melting point 150-160 ◦C
Table 6. Specifications of PPR-C
5.7 PPR-C pipe with Socket welded Samples
Figure 26. PPR-C pipe dia 40mm and Socket internal diameter is 40mm

5.8 Results
 After Tensile testing
Figure 27. Breaking of joint under tensile load
Figure 28. Breaking of joint under tensile load

5.9 Effect of RPM on Strength
The other parameters diameter = 40, Friction pressure = 7 Psi, Upset Pressure =
22 Psi, and Friction time = 8sec and Upset Forged time = 10sec are constant
throughout all observations.
Observations RPM Ultimate tensile strength
1 880 1.0983
2 1210 2 .2
3 1660 3.056
Table 7.Increasing the RPM
Graph 1. Effect of RPM on UTS
0
0.5
1
1.5
2
2.5
3
3.5
0 500 1000 1500 2000
UTS(Mpa)
RPM
Effect of RPM on UTS

5.10Effect of Friction Pressure on Strength
The other parameters diameter = 40mm, Rpm = 1660, Upset Pressure = 22
Psi, and Friction time = 8sec and Upset Forged time = 10sec are constant
Observations Friction pressure Ultimate tensile
strength
1 5 1.76
2 6 2.48
3 7 5.2
Table 8. Increasing the Friction Pressure
Graph 2. . Effect of friction pressure on UTS
0
0.5
1
1.5
2
2.5
3
3.5
0 10 20 30 40 50
UTS(Mpa)
Friction Pressure (Mpa)
Effect of Friction pressure on UTS

5.11Effect of Upset Pressure on Strength
The other parameters diameter = 40mm, Rpm = 1660, Friction pressure = 7 Psi,
and Friction time = 8sec and Upset Forged time = 10sec are constant
Observations Upset Pressure Ultimate tensile
strength
1 20 1.003
2 22 1.21
3 25 1.40
Table 9. Increasing the Upset Pressure
Graph 3. . Effect of forged pressure on UTS
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
0 0.05 0.1 0.15 0.2 0.25 0.3
UTS(Mpa)
Forged Pressure (Mpa)
Effect of Forged pressure

5.12Effect of Diameter on Strength
The other parameters upset pressure = 22 Psi, Rpm = 1660, Friction pressure = 7
Psi, and Friction time = 8sec and Upset Forged time = 10sec are constant throughout
all observations
observations Diameter (mm) Ultimate Tensile Strength (MPa)
1 26 0.565
2 32 1.6
3 40 2.9
Table 10. Increasing the Diameter
Graph 4. Effect of diameter on UTS
0
0.5
1
1.5
2
2.5
3
3.5
0 10 20 30 40 50
UTS(MPa)
Diameter (mm)
Effect of Diameter on UTS

5.13Discussion and Conclusion
The purpose of this work is was to join and assess the development of solid state joints of PPRC
pipes, via continuous drive friction welding process which combines the heat generated from friction
between two surfaces and plastic deformation. Test were conducted with different welding process
parameters. The results were analyzed by means of tensile testing to determine the phase that
occurred during welding.
The strength of the joint varied with increasing RPM, friction pressure, upset pressure, diameter of
work piece and time is constant throughout the processes. The joint strength is increased with
increasing all parameters.
Thus based on application we can manufacture work piece by the conclusion

6 References
1. Rombaut, P., W. De Waele, and K. Faes. Friction welding of steel to ceramic. in Sustainable
Construction and Design 2011 (SCAD). 2011. Ghent University, Laboratory Soete.
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Welding and Joining, 2007. 12(8): p. 738-759.
3. Sahin, M., Joining of stainless-steel and aluminium materials by friction welding. The
International Journal of Advanced Manufacturing Technology, 2009. 41(5-6): p. 487-497.
4. Duffin, F. and A. Bahrani, Frictional behaviour of mild steel in friction welding. Wear, 1973.
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friction process of steel friction welding. Journal of Solid Mechanics and Materials
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in tubular form. Welding Journal, 1962. 41(12): p. 542-550.
10. Nguyen TC, W.D., Metall Mater Trans B, 2006(37): p. 275–92.
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bars. Acta Materialia, 2008. 56(12): p. 2843-2855.
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142.
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journal of emerging technology and advanced engineering, 2012. 2(7): p. 200-210.
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Kenneth W. Johnson, pp. 694. ISBN 0-471-71398-8. Wiley-VCH, March 2005., 2005: p. 694.
15. https://www.quora.com/What-is-a-lathe-machine
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18. https://www.twi-global.com/capabilities/joining-technologies/friction-welding/rotary-
friction-welding/
19. Alves, E.P., et al., EXPERIMENTAL DETERMINATION OF TEMPERATURE DURING ROTARY
FRICTION WELDING OF AA1050 ALUMINUM WITH AISI 304 STAINLESS STEEL DOI
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