Advantages of Friction W Welding:

w No filler material, flux or shielding gases are needed.

* It is an environment-friendly process without generation of smoke, fume o

gases.

No material is melted so the process isrin solid state with namrow heat affected zone (HAZ).

Oxides can be removed after the welding process.

In mos cases, the weld strengt,h is stroniger than the weaker of the two materials being joined.

The process can be easily automated for mass production

. The process is very efficient and comparatively very rapid welds i are made.

Plant requiren

al and wide variety of metals and combinationis can be welded.

are m

Limitations of Friction W Welding:

The process is restricted to joini

round bars or tubes of same diameter (or bars tubes to flat

faces), capable of being rotated about the axis.

Dry bearing and non-forgeable materials cannot be welded. i.e. one of the compon

be ductile when hot, to permit deformations.

reparation and alignment of the workpieces may be critical for Seveloping uniform rubbing

and heating, particularly for pieces having diameters larger than 50 mm. -

Capital equipn and tooling costs are high and free-machining alloys are difficult to weld.

Applications of Friction Welding:

Friction welded parts i

agricultural,automotive, defense, ,marine and oil industries.

Right fiom tong holds to critical aircraft engine components are friction welded in

produe applications span over wide product for aerospace,

production.

Automotive parts that are friction weldded include gears, engine valves, axle tubes, sveline

componients, stiut rodsi dud shock abworbers

Hydraulic piston rods, track rollers, gears, bushiigs, axles and similar parts are cor
friction welde by the n

Friction welded aluminim/copper joints are in wide usage in the electrical industry.

Stainless steels are friction welded to carbon steels in various sizes for us

and water pumps for home and industrial use.

acturers of agricultural equipment.

t systems

v Friction welded assemblies are often used to replace expensive casting and forgings.

FRICTION STIR WELDING (FSW) :

Friction Stir Welding (FSW) is another variant process of friction weldina A schematic of the

FSW / is shown in Fig. 4.4.4.

The necessity and advent of Friction Stir Welding:

The basic problen with fision weldang of alunisnun and it allays ae hat hey powesk:

Cast brittle dendritic emuctiry,

Micro porosity,

anical and fatigive pr

5 Loss of strenigtbi in heat affecteil

e liowitol ca

aiweld pool

Loss of allo

The follow ing aftérwhte ech

aie beiig used forl joaning of aluini

and its alloys:

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