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Fig: Sequence of operation in the friction welding process 1)Left-hand component is rotated at high speed. 2)
Right-hand component is brought into contact under an axial force 3)Axial force is increased;the flash begins to
form 4) Left-hand component stops rotating;weld is completed.The flash can subsequently be removed by
machining or grinding
Friction Welding
• Process can be fully automated
Fig:Shape of friction zone in friction welding,as a function of the force applied and the rotational speed
Inertia Friction Welding
• Modification of Friction Welding
• Energy is supplied by a fly wheel
• The parts are pressed together by a normal force
• As friction at the interface increases, the fly wheel slows down
• The weld is completed when the flywheel stops
Friction stir welding can be used to join aluminium sheets and plates
without filler wire or shielding gas. Material thicknesses from 1.6 to 30
mm can be welded at full penetration and without porosity or internal
voids. High integrity welds with low distortion can be achieved in
many aluminium alloys, even those considered difficult to weld by
conventional fusion welding techniques. Materials that have been
successfully friction stir welded to date include a variety of aluminium
alloys (2xxx, 5xxx, 6xxx, 7xxx and 8xxx series) and Al-Li alloys.
More recently, friction stir welding has also been demonstrated for the
joining of lead, copper, magnesium and even titanium alloys.
Friction stir-weld, butt joint
between aluminium plates.
http://www.msm.cam.ac.uk/phase-trans/2003/FSW/aaa.html
A section through a friction stir
weld made in an Al-Si casting
alloy. There are pores indicated in
the base metal (BM). HAZ
represents the heat affected zone,
TMAZ the thermomechanically
affected zone, and SN the stir
nugget.