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Joining Technologies
Published in Raghu Echempati, Primer on Automotive Lightweighting Technologies, 2021
Friction welding is a solid-state welding process that uses the heat generated by friction (induced by relative mechanical movement) to join two materials. The parts to be joined are held together under pressure. Friction welding techniques are generally melt-free where the base materials are kept under their melting temperatures. The frictional heat causes a plastic zone (soft interface) between the parts to be joined. The applied external force presses the parts together and thus creates the joint. The combination of short processing times and the development of the heat directly at the interface results in fairly narrow heat-affected zones, also caused by upsetting a portion of the interface out of the weld joint during the process.
Joining of Dissimilar Materials Using Friction Welding
Published in Jaykumar J. Vora, Vishvesh J. Badheka, Advances in Welding Technologies for Process Development, 2019
Friction welding is a solid-state joining method, which is one of the most economical and highly productive methods for joining similar and dissimilar metals. It is widely used in automotive and aerospace component fabrication. It is often the only practical alternatives available in the joining domain available to overcome the difficulties encountered during the joining of the materials with widely varying physical properties (Uday et al. 2010, 534; James and Sudhish 2016, 1191; Winiezenko and Kaczorowski 2012, 444). Main advantages of friction welding are high materials saving, low production time, and the possibility of welding of dissimilar metals or alloys (Teker 2013, 303; Winiezenko and Kaczorowski 2012, 444).
Power Connectors
Published in Paul G. Slade, Electrical Contacts, 2017
Friction welding is a solid-state welding process in which the passion for welding is produced by direct conversion of mechanical energy to thermal energy at the contact interface without the application of external electrical energy or heat from other sources. Friction welds are created by taking a non-rotating work piece in a contact with a rotating work piece under constant or gradually increasing pressure until the interface reaches welding temperature and then the rotation is interrupted to complete the weld. The frictional heat produced at the interface rapidly raises the temperature of the work pieces, over a very short axial distance, values approaching but bellow the melting range. During the final stage of welding process, atomic diffusion occurs while the interfaces are in contact, allowing a metallurgical bond to form between the two fabrics. This welding process is used to make bimetallic aluminum-to-copper terminals and thus avoid direct contact between aluminum and copper. These terminals are usually copper flat plates or tubes friction welded to compression-type aluminum connectors. When installed, the friction welded terminals convert the aluminum-to-copper joint into an aluminum-aluminum and copper–copper joint. This type of a connector is widely used in Europe. Figure 5.95 illustrates a typical friction welded terminal.
Friction welding of high-strength casting nickel alloy VZh172L
Published in Welding International, 2022
V. I. Lukin, V. G. Kovalchuk, M. L. Samorukov, P. A. Kryuchkov
The use of the friction welding method, in comparison with fusion welding, provides following benefits:the possibility of obtaining joints with a strength close to the base material strength, including materials that cannot be welded by arc or beam welding methods;the absence of metal evaporation and ultraviolet radiation during the welding process;no need to use filler material and protective atmosphere (inert gasses, vacuum);saving of expensive materials due to the possibility to join dissimilar metals and alloys;low level of a residual stresses;minimal welding time;the possibility to automate the welding process.
Experimental analysis of mechanical properties of aluminium alloy weldments by friction welding process under cryogenic treatment
Published in International Journal of Ambient Energy, 2019
Friction welding briefs the contact of rotating work pieces moving relative to one another so as to produce heat by means of controlled rubbing of the facing surfaces. Friction welding has gained popularity because of several advantages; one among which is to weld alloys that cannot be welded in any other way. Due to the intensive heat generated at the interface, the material reaches the softened state which interacts with each other and produces good quality weld. In order to produce good quality weld joint, it is vital to set proper welding process parameters. Winiczenko and Kaczorowski (2013) investigated the mechanical properties and microstructure of friction welded couple of ductile iron with stainless steel. Scanning electron microscope was used for examination of the rupture morphology during friction welding process. The depth of Cr atoms penetration was reached up to 50 µm. The heat generated locally by friction increased the temperature in the area close to the interface even over the melting point of ductile iron and validated by metallographic which revealed the carbide eutectic enriched with Cr in ductile iron. Uday et al. (2012) established an analytical data for heat generation by friction welding, based on different parameters of the contact condition between two dissimilar materials. As a result, different data were evaluated for obtaining joint properties and operating conditions, and obtained results are useful in modelling the welding process and reliability joint under various conditions.