Tired of the old methods of joining materials? Then it’s time to discover friction welding: a process that has revolutionized the way materials are joined for the past 70 years.
With its rising popularity, this technique is being used in nearly every industrial process imaginable – from the aerospace and automotive industries to motor sports and underwater pipelines. Not only is friction welding faster, more cost-effective and more reliable than traditional joining processes, but it also produces superior bond strength — up to 85-95% of the base material strength. Incredible benefits aside, friction welding is also more environmentally friendly due to its minimal waste production and low levels of pollutants when compared to other processes.
It’s no wonder the industry is booming — its estimated market size is rapidly increasing, expecting to be a whopping $16 billion by 202
What is Friction Welding?Friction Welding is an advanced joining process that involves heat generated by friction between two rotating parts.
This process is used to join two similar or dissimilar metals permanently. It involves rapid rotation of one of the pieces, called the spindle, relative to the other piece, the job. The frictional heat that is generated melts the surfaces which are then joined when the rotation is stopped.
This joining process does not change the properties of the interface and does not require additional hardware, such as flux or solder.
How Does Friction Welding Work?
Friction welding is a two-step process that is divided into a pre-weld and a weld phase. The pre-weld phase involves the spindle and job pieces being brought together and the spindle being rapidly rotated before the weld phase begins. During the cycle, the job is under significant pressure until the correct temperature is achieved.
It is then held static in order to create a hermetic seal at the interface. The weld phase involves the spindle continuing to rotate until a pre-determined temperature is reached.
The weld phase then concludes with a cooling phase which allows the joint to solidify. During the welding process, the frictional heat generated causes the metal interfaces to expand and makes them to move closer together. This creates an intimate contact between the two parts that allows for an effective joint.