Development and Prospect of Friction Welding Technology

Introduction Resistance welding process is considered as a crucial spot welding technique. It is characterized by localized heat generation due to electrical and thermal resistance between the mating parts to create connection. This process can be used to weld materials like steel, aluminum, zinc......

Introduction

Resistance welding process is considered as a crucial spot welding technique. It is characterized by localized heat generation due to electrical and thermal resistance between the mating parts to create connection. This process can be used to weld materials like steel, aluminum, zinc, nickel and titanium, which are non-fusible. The welding can be done in the form of spot welding, projection welding, butt welding and flash welding.

Friction welding is one of the most predominant spot welding technique in which two parts are brought together under pressure and then rotated at very high speed. This generates heat and helps to join the parts and make them stronger, forming a permanent bond. Due to the improved yield strength of friction welded joints, it is used in the medical, automotive and aerospace industry in the joining of high precision parts and components.

Development of Friction Welding

Friction welding has been known since Ancient times. However, it has advanced significantly since it was initially used by archaeologists. After the development of arc welding, the idea of high speed rotation to provide the join was explored. Although the concept of friction welding was introduced before World War II, it was not until the late 1960s and early 1970s that the technology saw great development.

The development of friction welding was driven by the advancement of controls and automation. As technology became more advanced and powerful, the welding became easier, more reliable, and more efficient. Automation allowed for faster cycles with less production downtime and reduced cost.

This increased efficiency and cost saving also led to advancements in alloy welding technology. Higher levels of accuracy and repeatability became possible as the going technology developed. By combining the process of resist heat with rotating parts and metal sheets various weld was developed, including friction stir welding, friction riveting, friction impact welding and many others.

Application of Friction Welding

Friction welding is widely used in various weld assemblies and connections. These are mostly used in the manufacture of vehicle components such as axles, hip joints, clutches, disc brakes, and engine mounts. This process is also used in the production of medical equipment, including surgical instruments and devices.

In the aerospace industry, friction welding is used to make components such as pipes and pump housings. Its high strength and fatigue properties are useful in reducing vibration-induced fatigue problems. It is also used to make components for ships, aircrafts and constructions, such as propellers, structural bars, gears, and turntables.

In the automotive sector, this technique is used in the production of exhaust systems, suspension components, and brake systems. It is also used to join automotive components in transmissions, cooling systems, and suspensions.

Conclusion

Friction welding is an advanced spot welding technique that is increasingly being used in various industries. With the advancement of automated processes, it can create stronger bonds that have improved fatigue and shear resistance, as well as higher weld accuracy and repeatability. Thus, this welding technique is widely used in the automotive, medical, and aerospace industries. As technology continues to advance, new and improved welding techniques with increased efficiency and precision can be developed, enabling friction welding to be used in ever more varied applications.

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24/06/2023