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Friction welding
Friction welding (FWR) is a solid-state welding and bonding process that generates heat through mechanical friction between workpieces in relative motion to one another. The process is used with the addition of a lateral force called "upset" to plastically displace and fuse the materials. Friction welding is a solid-state welding technique similar to forge welding. Instead of a fusion welding process, friction welding is used with metals and thermoplastics in a wide variety of aviation and automotive applications.
The ISO norm of friction welding is EN ISO 15620:2019, which contains information about the basic terms, definitions, and tables of the weldability of metals and alloys.
Some applications and patents connected with friction welding dates back to the turn of the 20th century, with rotary friction welding (RFW) being the oldest of the methods. W. Richter patented the method of linear friction welding (LFW) process in 1924 in England and 1929 in the Weimar Republic. The description of the process was vague and H. Klopstock patented the process in the Soviet Union in 1924. The first description and experiments related to rotary friction welding took place in the Soviet Union in 1956, when a machinist named A. I. Chudikov researched scientific studies and suggested the use of the welding method as a commercial process. The process was introduced to the United States in 1960. The American companies Caterpillar Tractor Company (Caterpillar - CAT), Rockwell International, and American Manufacturing Foundry all developed machines for the process. Patents were also issued throughout Europe and the Soviet Union. The first studies of friction welding in England were carried out by the Welding Institute in 1961.
In the United States, Caterpillar Inc. and Manufacturing Technology Inc. (MTI) developed an inertia process in 1962. In Europe, KUKA AG and Thompson launched rotary friction welding for industrial applications in 1966, developed a direct-drive process, and in 1974, built the rRS6 double spindle machine for heavy truck axles. Another method was invented in the Soviet Union by Yu. Klimenko in the mid-1960s and patented in 1967, experimentally proven and developed into a commercial technology at The Welding Institute (TWI) in the United Kingdom and patented again in 1991: the friction stir welding (FSW) process, is a solid-state joining process that uses a non-consumable tool to join two facing workpieces without melting the workpiece material.
An improved modification of the standard friction welding technique is low force friction welding, a hybrid technology developed by EWI and MTI, which "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". The process applies to both linear and rotary friction welding.
Friction welding takes many forms but the following are the most popular methods used.
Rotary friction welding (RFW) is one of the main methods of friction welding. One welded element is rotated relative to the other and pressed down. The heating of the material is caused by friction work and creates a non-separable weld.
Radial friction welding is a type of friction welding similar to rotary friction welding and is generally used to weld pipes together. However, unlike Rotary friction welding, it does not require either of the parts to be rotated. Instead a ring is used to generate the necessary heat by rotating it around the pipes.
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Friction welding
Friction welding (FWR) is a solid-state welding and bonding process that generates heat through mechanical friction between workpieces in relative motion to one another. The process is used with the addition of a lateral force called "upset" to plastically displace and fuse the materials. Friction welding is a solid-state welding technique similar to forge welding. Instead of a fusion welding process, friction welding is used with metals and thermoplastics in a wide variety of aviation and automotive applications.
The ISO norm of friction welding is EN ISO 15620:2019, which contains information about the basic terms, definitions, and tables of the weldability of metals and alloys.
Some applications and patents connected with friction welding dates back to the turn of the 20th century, with rotary friction welding (RFW) being the oldest of the methods. W. Richter patented the method of linear friction welding (LFW) process in 1924 in England and 1929 in the Weimar Republic. The description of the process was vague and H. Klopstock patented the process in the Soviet Union in 1924. The first description and experiments related to rotary friction welding took place in the Soviet Union in 1956, when a machinist named A. I. Chudikov researched scientific studies and suggested the use of the welding method as a commercial process. The process was introduced to the United States in 1960. The American companies Caterpillar Tractor Company (Caterpillar - CAT), Rockwell International, and American Manufacturing Foundry all developed machines for the process. Patents were also issued throughout Europe and the Soviet Union. The first studies of friction welding in England were carried out by the Welding Institute in 1961.
In the United States, Caterpillar Inc. and Manufacturing Technology Inc. (MTI) developed an inertia process in 1962. In Europe, KUKA AG and Thompson launched rotary friction welding for industrial applications in 1966, developed a direct-drive process, and in 1974, built the rRS6 double spindle machine for heavy truck axles. Another method was invented in the Soviet Union by Yu. Klimenko in the mid-1960s and patented in 1967, experimentally proven and developed into a commercial technology at The Welding Institute (TWI) in the United Kingdom and patented again in 1991: the friction stir welding (FSW) process, is a solid-state joining process that uses a non-consumable tool to join two facing workpieces without melting the workpiece material.
An improved modification of the standard friction welding technique is low force friction welding, a hybrid technology developed by EWI and MTI, which "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". The process applies to both linear and rotary friction welding.
Friction welding takes many forms but the following are the most popular methods used.
Rotary friction welding (RFW) is one of the main methods of friction welding. One welded element is rotated relative to the other and pressed down. The heating of the material is caused by friction work and creates a non-separable weld.
Radial friction welding is a type of friction welding similar to rotary friction welding and is generally used to weld pipes together. However, unlike Rotary friction welding, it does not require either of the parts to be rotated. Instead a ring is used to generate the necessary heat by rotating it around the pipes.