Sear
Friction welding
Friction welding (FRW) is a solid-st at e welding process t hat generat es heat t hrough mechanical
frict ion bet ween workpieces in relat ive mot ion t o one anot her, wit h t he addit ion of a lat eral force
called "upset " t o plast ically displace and fuse t he mat erials. Because no melt ing occurs, frict ion
welding is not a fusion welding process, but a solid-st at e welding t echnique more like forge
welding. Frict ion welding is used wit h met als and t hermoplast ics in a wide variet y of aviat ion and
aut omot ive applicat ions.
ISO norm of frict ion welding is EN ISO 15620:2019[1] t here is informat ion about basic t erms and
definit ions and t able of weldabilit y of met als and alloys.
History
Historical photo of double spindle machine of rotary friction welding..
Some applicat ions and pat ent s connect ed wit h frict ion welding were dat ed back t o t he t urn of
t he 20t h cent ury[2] and rot ary frict ion welding is t he oldest of t his met hods.[3] W. Richt er
pat ent ed t he met hod of linear frict ion welding (LFW) process in 1924[4] in England and 1929[4] in
Germany, however, t he descript ion of t he process was vague [3] and H.Klopst ock pat ent ed t he
same process in t he USSR 1924.[4] But first descript ion and experiment s relat ed t o rot ary frict ion
welding t ook place in t he Soviet Union in 1956,[2][4] machinist named A. J. Chdikov has realized
scient ific st udies and suggest ed t he use of t his welding met hod as a commercial process.[4] The
process was int roduced t o t he USA in 1960.[2] The American companies Cat erpillar Tract or
Company (Cat erpillar - CAT), Rockwell Int ernat ional, and American Manufact uring Foundry all
developed machines for t his process. Pat ent s were also issued t hroughout Europe and t he
former Soviet Union. The first st udies of frict ion welding in England were carried out by t he
Welding Inst it ut e in 1961.[4] The USA wit h Cat erpillar Inc. and MTI developed an inert ia process in
1962.[2][4] Europe wit h KUKA AG and Thompson launches rot ary frict ion welding for indust rial
applicat ions in 1966,[5] developed a direct -drive process and in 1974[5] builds rRS6 t he double
spindle machine for heavy t ruck axles.[5] Anot her met hod was invent ed and experiment ally
proven at The Welding Inst it ut e (TWI) in t he UK and pat ent ed in 1991 Frict ion st ir welding (FSW)
process[6] a solid-st at e joining process t hat uses a non-consumable t ool t o join t wo facing
workpieces wit hout melt ing t he workpiece mat erial. In 2008 KUKA AG developed t he frict ion
welding machine SRS 1000 wit h a forged force of 1000 t ons.[5]
An improved modificat ion of t he st andard frict ion welding is also Low Force Frict ion Welding (ht t
ps://blog.mt iwelding.com/low-force-frict ion-welding) , hybrid t echnology developed by EWI and
Manufact uring Technology Inc. (MTI), "uses an external energy source to raise the interface
temperature of the two parts being joined, thereby reducing the process forces required to make a
solid-state weld compared to traditional friction welding".[7] The process applies t o bot h linear and
rot ary frict ion welding.
Today, t he frict ion welding research mat erials comes from many places around t he world,
including Africa, Sout h America, Nort h America, Europe and Asia, and Aust ralia.
Metal techniques
Rotary friction welding
…
Rotary friction welding
Rot ary frict ion welding (RFW) is one of t he met hods of frict ion welding. One welded element is
rot at ed t o t he ot her and pressed down. The heat ing of t he mat erial is caused by frict ion work
and creat ed not separable weld.
Linear friction welding
…
Linear frict ion welding (LFW) is similar t o spin welding, except t hat t he moving chuck oscillat es
lat erally inst ead of spinning.
Friction stir welding
…
Friction stir welding
Frict ion st ir welding (FSW) is a solid-st at e joining process t hat uses a non-consumable t ool t o
join t wo facing workpieces wit hout melt ing t he workpiece mat erial. Heat is generat ed by frict ion
bet ween t he rot at ing t ool and t he workpiece mat erial, which leads t o a soft ened region near t he
FSW t ool. While t he t ool is t raversed along t he joint line, it mechanically int ermixes t he t wo
pieces of met al, and forges t he hot and soft ened met al by t he mechanical pressure, which is
applied by t he t ool, much like joining clay, or dough.
Friction surfacing
…
Frict ion surfacing is a process derived from frict ion welding where a coat ing mat erial is applied t o
a subst rat e. A rod composed of t he coat ing mat erial (called a mecht rode) is rot at ed under
pressure, generat ing a plast icized layer in t he rod at t he int erface wit h t he subst rat e.
Thermoplastic technique
Linear vibration welding
…
In linear vibrat ion welding t he mat erials are placed in cont act and put under pressure. An ext ernal
vibrat ion force is t hen applied t o slip t he pieces relat ive t o each ot her, perpendicular t o t he
pressure being applied.
Orbital friction welding
…
Orbit al frict ion welding is similar t o spin welding, but uses a more complex machine t o produce an
orbit al mot ion in which t he moving part rot at es in a small circle, much smaller t han t he size of t he
joint as a whole.
Method list connected to friction welding
Forge welding
Frict ion st ir welding (FSW)[6]
Frict ion st ir spot welding (FSSW)[8]
Linear frict ion welding (LFW)[9][10]
Frict ion welding of pipeline girt h welds (FRIEX)[11]
Frict ion hydro pillar overlap processing (FHPPOW)[12]
Frict ion hydro pillar processing (FHHP)[13]
Linear vibrat ion welding
Spin welding of polymers
Low Force Frict ion Welding[7]
Other information
Welds tests for Friction Welding and description of zones
…
Qualit y requirement s of welded joint s depend on t he form of applicat ion, e.g. in t he space or fly
indust ry weld errors are not allowed.[14] There are many scient ific art icles describing t he weld,
weld qualit y t est s assurance is performed, wit h measurement s and numerical met hods. Science
t ries t o get s good qualit y welds.
For example, an ult ra fine grain st ruct ure of alloy or met al which is obt ained by t echniques such
as severe plast ic deformat ion[15] is desirable, and not changed by t he high t emperat ure, a large
heat affect ed zone is unnecessary.[16][10]
Moreover, in addit ion t o changing t he grain st ruct ure during met al joining cycles, by met hods
where high t emperat ure affect ed zone was occur, are phase t ransformat ions st ruct ure. For
example, in st eel bet ween aust enit e, ferrit e, pearlit e, bainit e,[17] cement it e and mart ensit e, see:
Iron-carbon phase diagram. In order t o avoid changes solid st at e welding may be desired and
large heat affect ed zone is not needed if weakens t he mat erial propert ies.
Heat and mechanical affected zones in friction weld
Picture shows weld zones in friction welding.[9]
…
Individual t hermomechanical zones can be described by cit ing an example art icle:
Ant hony R.McAndrew, Paul A.Colegrove, Clement Bühr, Bert rand C.D., Flipo Achilleas Vairis, "A
lit erat ure review of Ti-6Al-4V linear frict ion welding (ht t ps://www.sciencedirect .com/science/art
icle/pii/S0079642517301275) ", 2018.[9]
"Technically the WCZ and the TMAZ are both "thermo-mechanically affected zones" but due to the
vastly different microstructures they possess they are often considered separately. The WCZ
experiences significant dynamic recrystallisation (DRX), the TMAZ does not. The material in HAZ is
not deformed mechanically but is affected by the heat. The region from one TMAZ/HAZ boundary
to the other is often referred to as the "TMAZ thickness" or the plastically affected zone (PAZ). For
the remainder of this article this region will be referred to as the PAZ."[18]
Zones:
WCZ– weld cent er zone,
HAZ – heat affect ed zone,
TMAZ – Thermo-Mechanically Affect ed Zone,
BM – base mat erial, parent mat erial,
Flash.
Similar t erms exist in welding.
Seizure resistance
…
Frict ion welding may unint ent ionally occur at sliding surfaces like bearings. This happens in
part icular if t he lubricat ing oil film bet ween sliding surfaces becomes t hinner t han t he surface
roughness, which may be due t o low speed, low t emperat ure, oil st arvat ion, excessive clearance,
low viscosit y of t he oil, high roughness of t he surfaces, or a combinat ion t hereof.[19]
The seizure resist ance is t he abilit y of a mat erial t o resist frict ion welding. It is a fundament al
propert y of bearing surfaces and in general of sliding surfaces under load.
Curiosities
Frict ional welding (μFSW) was also performed using a CNC machine.[20] which does not mean
t hat it is safe and recommended for t he milling machine.
…
Frict ion welding has also been shown t o work on wood.[21][22][23]
Terms and definitions, name shortcuts
To quot e ISO (t he Int ernat ional Organizat ion for St andardizat ion) - ISO 15620:2019(en) Welding
— Frict ion welding of met allic mat erials (ht t ps://www.iso.org/obp/ui/#iso:st d:iso:15620:ed-2:v1:
en) :
"axial force - force in axial direct ion bet ween component s t o be welded,
burn-off length - loss of lengt h during t he frict ion phase,
burn-off rate - rat e of short ening of t he component s during t he frict ion welding process,
component - single it em before welding,
component induced braking - reduct ion in rot at ional speed result ing from frict ion bet ween t he
int erfaces,
external braking - braking locat ed ext ernally reducing t he rot at ional speed,
faying surface - surface of one component t hat is t o be in cont act wit h a surface of anot her
component t o form a joint ,
forge force - force applied normal t o t he faying surfaces at t he t ime when relat ive movement
bet ween t he component s is ceasing or has ceased,
forge burn-off length - amount by which t he overall lengt h of t he component s is reduced
during t he applicat ion of t he forge force,
forge phase - int erval t ime in t he frict ion welding cycle bet ween t he st art and finish of
applicat ion of t he forge force,
forge pressure - pressure (force per unit area) on t he faying surfaces result ing from t he axial
forge force,
forge time - t ime for which t he forge force is applied t o t he component s,
friction force - force applied perpendicularly t o t he faying surfaces during t he t ime t hat t here is
relat ive movement bet ween t he component s,
friction phase - int erval t ime in t he frict ion welding cycle in which t he heat necessary for
making a weld is generat ed by relat ive mot ion and t he frict ion forces bet ween t he component s
i.e. from cont act of component s t o t he st art of decelerat ion,
friction pressure - pressure (force per unit area) on t he faying surfaces result ing from t he axial
frict ion force,
friction time - t ime during which relat ive movement bet ween t he component s t akes place at
rot at ional speed and under applicat ion of t he frict ion forces,
interface - cont act area developed bet ween t he faying surfaces aft er complet ion of t he
welding operat ion,
rotational speed - number of revolut ions per minut e of rot at ing component ,
stick-out - dist ance a component st icks out from t he fixt ure, or chuck in t he direct ion of t he
mat ing component ,
deceleration phase - int erval in t he frict ion welding cycle in which t he relat ive mot ion of t he
component s is decelerat ed t o zero,
deceleration time - t ime required by t he moving component t o decelerat e from frict ion speed
t o zero speed,
total length loss (upset) - loss of lengt h t hat occurs as a result of frict ion welding, i.e. t he sum
of t he burn-off lengt h and t he forge burn-off lengt h,
total weld time - t ime elapsed bet ween component cont act and end of forging phase,
welding cycle - succession of operat ions carried out by t he machine t o make a weldment and
ret urn t o t he init ial posit ion, excluding component - handling operat ions,
weldment - t wo or more component s joined by welding."[1]
References
1. "EN ISO 15620:2019" (https://www.iso.org/obp/ui/#iso:std:iso:15620:ed-2:v1:en) . www.iso.org.
Retrieved 2020-12-28.
2. Wen Lin, K. K. Wang (1974). "Flywheel Friction Welding Research" (https://app.aws.org/wj/supplement/
WJ_1974_06_s233.pdf)
(PDF). Supplement to the Welding Journal.
3. J. LOPERA, K. MUCIC, F. FUCHS, N. ENZINGER (October 2012). "Linear Friction Welding Of High
Strength Chains: Modelling And Validation" (https://www.researchgate.net/publication/292091334) .
Mathematical Modelling of Weld Phenomena. 10.
4. Mehmet UZKUT, Bekir Sadık ÜNLÜ, Selim Sarper YILMAZ, Mustafa AKDAĞ. "Friction Welding And Its
Applications In Today's World" (https://core.ac.uk/download/pdf/153447357.pdf)
(PDF).
5. "Rotary friction welding machines" (https://www.kuka.com/en-us/products/production-machines/rotaryfriction-welding-machines) . KUKA AG. Retrieved 2020-12-27.
. Thomas, W.M., Nicholas, E.D., Needham, J.C., Murch, M.G., Templesmith, P., Dawes, C. J., 1991.
Improvements to Friction Welding. GB Patent Application No. 91259788.
7. Jones, Simon. "Low Force Friction Welding -- What is it?" (https://blog.mtiwelding.com/low-force-frictionwelding) . blog.mtiwelding.com. Retrieved 2020-12-28.
. Lacki, P.; Kucharczyk, Z.; Śliwa, R.E.; Gałaczyński, T. (2013-06-01). "Effect of Tool Shape on Temperature
Field in Friction Stir Spot Welding" (https://doi.org/10.2478%2Famm-2013-0043) . Archives of
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7.10.003) . Progress in Materials Science. 92: 225–257. doi:10.1016/j.pmatsci.2017.10.003 (https://d
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1 . Clement Bühr, Paul A.Colegrove, Bertrand C.D.Flipo, Achilleas Vairis, Anthony R.McAndrew (2018-0301). "A literature review of Ti-6Al-4V linear friction welding" (https://doi.org/10.1016%2Fj.pmatsci.2017.1
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