This document discusses friction welding and its types. Friction welding is a solid-state joining process that generates heat through friction between surfaces to join materials. There are three main types: continuous driven welding uses rotation to induce friction; flywheel driven welding uses a flywheel to achieve rotation; and a combination method uses aspects of both. Friction stir welding is also covered, which uses a rotating tool to mechanically stir and mix materials to weld instead of using the parts themselves. Examples of friction welding applications are provided.

1. Friction Welding
By: Yitagesu Tesfaye
Student at Debre Berhan University
Mechanical Engineering Department
By: Yitagesu Tesfaye

2. Friction Welding
Contents
Introduction to welding
Friction welding
Types of friction Welding
Friction Stir Welding
By: Yitagesu Tesfaye

3.  Introduction to Welding
 Welding: is a materials joining process in which
two or more parts are coalesced at their contacting
surfaces by a suitable application of heat and/or
pressure.
Types of Welding
 generally welding have the following types
 Friction Welding
 Ultrasonic welding
 Diffusion welding
 Laser beam welding
 Electron beam welding
 Resistance welding
 Plasma arc welding
By: Yitagesu Tesfaye

4.  Gas Tungsten arc welding(GTAW)
 Submerged arc welding(SAW)
 Electro gas welding(EGW)
 Flux cored arc welding(FCAW)
 Gas metal arc welding(GMAW)
Among those types we discusses
about friction welding .
By: Yitagesu Tesfaye

5. Friction Welding
 It is a solid-state joining process
 produces coalescence in materials,
using the heat developed between
surfaces through a combination of
mechanically induced rubbing motion
and applied load.
 the heat required for welding is
generated through (as the name
implies) friction at the interface of the
two components being joined.
By: Yitagesu Tesfaye

6.  During the welding process, surfaces are under
pressure and this period called the heating phase
continues until plastic forming temperature is
achieved.
 The temperature in the welding region for steels
is between 900 and 1300 oC. Heated metal at the
interface accumulates by increasing pressure
after heating phase.
 The friction is induced by mechanical rubbing
between the two surfaces, usually by rotation of
one part relative to the other, to raise the
temperature at the joint interface to the hot
working range for the metals involved.
 Then the parts are driven toward each other with
sufficient force to form a metallurgical bond.
By: Yitagesu Tesfaye

7. By: Yitagesu Tesfaye

8.  Types of friction welding
A. Continuous driven friction
welding
B. Flywheel driven friction welding
C. Combination of the two
By: Yitagesu Tesfaye

9. A. continuous driven friction
welding
 Mechanical energy is converted to heat
by applying pressure from rotating part to
non-rotating part.
 One of the parts is connected to the
engine inducement unit and rotates at a
constant velocity; a constant axial force
is applied to parts. Working parts interact
with each other during welding or until
axial shortening occurs. Then, braking
system stops the process.
By: Yitagesu Tesfaye

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11. B. Flywheel drive friction
welding
 flywheel induced system constantly
rotates and is joined to flywheel shaft
system to achieve a certain speed.
 After reaching a certain speed, engine
flywheel is separated from shaft
flywheel. Shaft flywheel having a low
moment of inertia stops without
braking. Therefore, this welding
method is known as welding of inertia
.
By: Yitagesu Tesfaye

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13. C. Combination of the two
 This method is also sometimes termed
as flywheel induced friction welding.
The essential welding parameters are
rpm, friction force on the surface, the
length of friction time, and forging time
on the surface, forging time and time
of brake.
By: Yitagesu Tesfaye

14.  Friction Stir Welding
 It is a solid state welding process in
which a rotating tool is fed along the
joint line between two work pieces,
generating friction heat and
mechanically stirring the metal to form
the weld seam.
 FSW is distinguished from
conventional FRW by the fact that
friction heat is generated by a
separate wear-resistant tool rather
than by the parts themselves.By: Yitagesu Tesfaye

15.  The rotating tool is stepped, consisting
of a cylindrical shoulder and a smaller
probe
projecting beneath it. During welding,
the shoulder rubs against the top
surfaces of the two parts, developing
much of the friction heat, while the
probe generates additional heat by
mechanically mixing the metal along
the butt surfaces. The probe has a
geometry designed to facilitate the
mixing action.
By: Yitagesu Tesfaye

16. Advantages
 Good mechanical properties of the weld
joint
 Avoidance of toxic fumes, warping,
shielding issues and other problems
associated with arc welding
 Little distortion or shrinkage
 good weld appearance.
Disadvantages
 An exit hole is produced when the tool is
withdrawn from the work, and
 Heavy-duty clamping of the parts is
required.
By: Yitagesu Tesfaye

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18. Some examples of
applications of friction welding
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