Friction Welding 1rr3e
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FRICTION WELDING
Friction Welding Lesson Objectives When you finish this lesson you will understand: • Continuous Drive Friction Welding & Applications • Variables Effecting Friction Welding • Variations of friction Welding Process • Dissimilar Materials Welded • Inertia Welding Process & Applications
Learning Activities 1. View Slides; 2. Read Notes, 3. Listen to lecture 4. Do on-line workbook 5. View Video
Keywords: Friction Welding, Inertia Welding, Forging Pressure, Orbital Friction Welding, Linear Friction Welding, Angular Reciprocating Friction Welding, Radial Friction Welding, Friction Stir Welding
Electrical
Solid State Welding
Chemical Friction Mechanical
Pressure & Deformation
Friction Weld
Definition of Friction Welding • Friction welding is a solid state ing process that produces coalescence by the heat developed between two surfaces by mechanically induced surface motion.
Examine the Friction Weld Video on the Web Page Link to Friction Welding Video
Categories of Friction Welding • Continuous drive • Inertia
Continuous Drive
Continuous Drive Friction Welding • One of the workpieces is attached to a rotating motor drive, the other is fixed in an axial motion system. • One workpiece is rotated at constant speed by the motor. • An axial or radial force is applied.
Workpieces Motor
Spindle Chuck Brake
Non-rotating vise
Hydraulic cylinder
Continuous Drive
Continuous Drive Friction Welding • The work pieces are brought together under pressure for a predetermined time, or until a preset upset is reached. • Then the drive is disengaged and a break is applied to the rotating work piece.
Workpieces Motor
Spindle Chuck
Brake
Non-rotating vise
Hydraulic cylinder
Linnert, Welding Metallurgy, AWS, 1994
Continuous Drive
Friction Welding Variables (Continuous Drive)
• • • • • •
Rotational speed Heating pressure Forging pressure Heating time Braking time Forging time
AWS Welding Handbook
AWS Welding Handbook
AWS Welding Handbook
Equipment
Direct Drive Machine
Courtesy AWS handbook
Friction Welding Process Variations
AWS Welding Handbook
Continuous Drive
Friction Welding t Design • The t face of at least one of the work piece must have circular symmetry (usually the rotating part). • Typical t configurations shown at right.
Rod
Rod to plate
Tube
Rod to tube
Tube to plate
Tube to disc
Orbital Friction Welding AWS Welding Handbook
Angular Reciprocating Friction Welding AWS Welding Handbook
Linear Reciprocating Friction Welding AWS Welding Handbook
Radial Friction Welding F
• Used to collars to shafts and tubes. • Two tubes are clamped in fixed position. The collar to be ed is placed between the tubes. • The collar is rotated producing frictional heat. • Radial forces are applied to compress the collar to complete welding.
F
F
+
F
F F
F
F
F
Friction Surfacing AWS Welding Handbook
Friction Stir Welding • Parts to be ed are clamped firmly. • A rotating hardened steel tool is driven into the t and traversed along the t line between the parts. • The rotating tool produces friction with the parts, generating enough heat and deformation to weld the parts together.
Butt welds
Overlap welds
Friction Stir Welding
Clamping force
Step -1
clamping force
Step -3
Step -4
Step -2
Friction Stir Welding
900
Corner welds
T-section ( 2- component top butt)
Friction Stir Welding
Fillet butt welds
Continuous Drive
Friction Welding Applications • Frequently competes with flash or upset welding when one of the work pieces to be ed has axial symmetry. • Used in automotive industry to manufacture gears, engine valves, and shock absorbers. • Used to jet engine compressor parts.
Applications
Friction Welded ts
Friction Welded t
Friction Welded Automotive Halfshaft
Courtesy AWS handbook
Applications
Friction Welded ts
Cross Section of Aluminum Automotive Airbag Inflator. Three Welds Are Made Simultaneously
Camshaft Forging Friction Welded To Timing Gear.
Courtesy AWS handbook
Applications
Friction Welds
Inertia Welded Hand Tools
A Jet Engine Compressor Wheel Fabricated by Friction Welding
Courtesy AWS handbook
Dissimilar Metals – Friction Welded
Aluminum to Steel Friction Weld
AWS Welding Handbook
Photomicrograph of Aluminum (top) to Steel (bottom) AWS Welding Handbook
Friction Weld Tantalum to Stainless Steel Note: mechanical mixing
AWS Welding Handbook
Continuous Drive Friction Weld of Titanium Pipe
Ti-6Al-4V-0.5Pd 246 mm diameter 14mm wall thickness No shielding used
Center
HAZ
Froes, FH, et al, “Non-Aerospace Applications of Titanium” Feb 1998, TMS
Radial friction weld of Ti-6Al-4V-0.1Ru
Properties in Weld Better than Base Metal
Froes, FH, et al, “Non-Aerospace Applications of Titanium” Feb 1998, TMS
Linear Friction Weld Repair of Fan Blades
Fan
Turbine Compressor Combustor
Walker, H, et al, “Method for Linear Friction Welding and Products made by such Method” US Patent 6,106,233 Aug 22, 2000
Friction Welding for Mounting Ti Alloy Rotor Blades
Shielding Gas & Induction Pre-heat
Weld Nub
Force
Linear Friction Weld
Schneefeld, D,et al. “Friction Welding Process for Mounting Blades of a Rotor for a Flow Machine”, US Patent 6,160,237 Dec 12, 2000
Friction Welding Connector to Imbedded Window Wires
Glass
White, D et al, “Friction Welding NonMetallics to Metallics”, US Patent 5,897,964 Apr. 27, 1999
Wire Conductor
Silver Based Ceramic Paint
Friction Stir Welding – Tool Design Modification
Hard Tool Tip Buried in Work Piece
Metal Flow
Force
Travel Speed Midling, O, et al, “Friction Stir Welding” US Patent 5,813,592 Sep. 29, 1998
Friction Stir Welding – Automation Moving Device
Elevation Platform and fixture device
Friction Stir Welder
Mobile System Ding, R. et al, “Friction Stir Weld System for Welding and Weld Repair”, US Patent 6,173,880 Jan 16, 2001
Inertia Welding
Inertia Drive
Inertia Welding Process Description • One of the work pieces is connected to a flywheel; the other is clamped in a nonrotating axial drive • The flywheel is accelerated to the welding angular velocity. • The drive is disengaged and the work pieces are brought together. • Frictional heat is produced at the interface. An axial force is applied to complete welding.
Motor Flywheel
Spindle
Non-rotating chuck Workpieces
Chuck Hydraulic cylinder
Inertia Welding 2
IS E C
E Eu A
Where E = Energy, ft-lb (J) I = Moment of Inertia, lb-ft2 ( kg-m2) S = Speed, rpm C = 5873 when the moment of inertia is in lb-ft2 C = 182.4 when the moment of inertia is in kg-m2 Eu = Unit Energy, ft-lb/in2 (J/mm2) A = Faying Surface Area
Inertia Drive
Inertia Welding Variables • • • •
Moment of inertia of the flywheel. Initial flywheel speed. Axial pressure. Forging pressure.
Linnert, Welding Metallurgy, AWS, 1994
Equipment
Inertia Welding Machine
Courtesy AWS handbook
Linnert, Welding Metallurgy, AWS, 1994
A Few Specific Examples
Super-speed (750 SFM) Inertia Welding of Jet Turbine Components Part Stator components Combustor Casing Low pressure turbine casing Other Parts
Ave. Diameter Range (in.) 10-80 42
Waspaloy
72
Waspaloy
various
Inconel Waspaloy Hastelloy Rene
Problems • Melting Destroys Properties • Low (200F) Forging Temp Range – Need Precise Control
Ablett, AM et al, “Superspeed Inertia Welding”, US Patenmt 6,138,896, Oct. 31, 2000
Super-speed (750 SFM) Inertia Welding of Jet Turbine Components Control Parameters • Workpiece Geometry (size) • Applied Weld Load Stress) • Initial Speed (surface velocity • Unit Energy Input (moment of inertia, radius of gyration) E WK 2 RPM 2 / 5873 A RPM 12SFM / D Where
E = unit energy input W = flywhel weight K = radius of gyration RPM = initial rotation SFM = speed D = diameter A = area
Ablett, AM et al, “Superspeed Inertia Welding”, US Patenmt 6,138,896, Oct. 31, 2000
Titanium Engine Valve
Inertia Weld Titanium Aluminides or Titanium Borides
Titanium Alloy (Ductile)
(Brittle at RT)
Jette, P , Sommer, A., “Titanium Engine Valve”, US Patent 5,517,956 May 21, 1996
Inertia Welding of Magnesium and Aluminum Wheels for Motor Vehicles Wheel Aluminum Mg AM60 Mg AM60 Mg AE42
Inertia Weld
Hot Inert Shielding Gas
Spider Magnesium Mg AE42 Mg AZ91 Mg AZ91
Welding parameters determined by the lower-deforming alloy or the alloy with higher melting point
Separautzki, R,et al, “Process for Manufacturing a Wheel for a Motor Vehicle” US Patent 6,152,351 Nov 28, 2000
Similarities between Continuous Drive and Inertia Drive • In both methods, welding heat is developed by frictional heat and plastic deformation. • Both methods use axial force for upsetting purpose. • In both methods the axial pressure may be changed (usually raised) at the end of rotation.
Differences between Continuous Drive and Inertia Drive
Continuous drive
Inertia drive
• One of the workpieces • One of the workpieces is directly connected to a connected to the flywheel. rotating motor drive. • Rotational speed decreases • Rotational speed remains continuously to zero during constant until the brake is the process. applied. • Kinetic energy of the • Rotational energy of the flywheel dissipates through workpiece dissipates through friction and plastic friction and plastic deformation producing heat. deformation, producing welding heat.
Friction Welding Lesson Objectives When you finish this lesson you will understand: • Continuous Drive Friction Welding & Applications • Variables Effecting Friction Welding • Variations of friction Welding Process • Dissimilar Materials Welded • Inertia Welding Process & Applications
Learning Activities 1. View Slides; 2. Read Notes, 3. Listen to lecture 4. Do on-line workbook 5. View Video
Keywords: Friction Welding, Inertia Welding, Forging Pressure, Orbital Friction Welding, Linear Friction Welding, Angular Reciprocating Friction Welding, Radial Friction Welding, Friction Stir Welding
Electrical
Solid State Welding
Chemical Friction Mechanical
Pressure & Deformation
Friction Weld
Definition of Friction Welding • Friction welding is a solid state ing process that produces coalescence by the heat developed between two surfaces by mechanically induced surface motion.
Examine the Friction Weld Video on the Web Page Link to Friction Welding Video
Categories of Friction Welding • Continuous drive • Inertia
Continuous Drive
Continuous Drive Friction Welding • One of the workpieces is attached to a rotating motor drive, the other is fixed in an axial motion system. • One workpiece is rotated at constant speed by the motor. • An axial or radial force is applied.
Workpieces Motor
Spindle Chuck Brake
Non-rotating vise
Hydraulic cylinder
Continuous Drive
Continuous Drive Friction Welding • The work pieces are brought together under pressure for a predetermined time, or until a preset upset is reached. • Then the drive is disengaged and a break is applied to the rotating work piece.
Workpieces Motor
Spindle Chuck
Brake
Non-rotating vise
Hydraulic cylinder
Linnert, Welding Metallurgy, AWS, 1994
Continuous Drive
Friction Welding Variables (Continuous Drive)
• • • • • •
Rotational speed Heating pressure Forging pressure Heating time Braking time Forging time
AWS Welding Handbook
AWS Welding Handbook
AWS Welding Handbook
Equipment
Direct Drive Machine
Courtesy AWS handbook
Friction Welding Process Variations
AWS Welding Handbook
Continuous Drive
Friction Welding t Design • The t face of at least one of the work piece must have circular symmetry (usually the rotating part). • Typical t configurations shown at right.
Rod
Rod to plate
Tube
Rod to tube
Tube to plate
Tube to disc
Orbital Friction Welding AWS Welding Handbook
Angular Reciprocating Friction Welding AWS Welding Handbook
Linear Reciprocating Friction Welding AWS Welding Handbook
Radial Friction Welding F
• Used to collars to shafts and tubes. • Two tubes are clamped in fixed position. The collar to be ed is placed between the tubes. • The collar is rotated producing frictional heat. • Radial forces are applied to compress the collar to complete welding.
F
F
+
F
F F
F
F
F
Friction Surfacing AWS Welding Handbook
Friction Stir Welding • Parts to be ed are clamped firmly. • A rotating hardened steel tool is driven into the t and traversed along the t line between the parts. • The rotating tool produces friction with the parts, generating enough heat and deformation to weld the parts together.
Butt welds
Overlap welds
Friction Stir Welding
Clamping force
Step -1
clamping force
Step -3
Step -4
Step -2
Friction Stir Welding
900
Corner welds
T-section ( 2- component top butt)
Friction Stir Welding
Fillet butt welds
Continuous Drive
Friction Welding Applications • Frequently competes with flash or upset welding when one of the work pieces to be ed has axial symmetry. • Used in automotive industry to manufacture gears, engine valves, and shock absorbers. • Used to jet engine compressor parts.
Applications
Friction Welded ts
Friction Welded t
Friction Welded Automotive Halfshaft
Courtesy AWS handbook
Applications
Friction Welded ts
Cross Section of Aluminum Automotive Airbag Inflator. Three Welds Are Made Simultaneously
Camshaft Forging Friction Welded To Timing Gear.
Courtesy AWS handbook
Applications
Friction Welds
Inertia Welded Hand Tools
A Jet Engine Compressor Wheel Fabricated by Friction Welding
Courtesy AWS handbook
Dissimilar Metals – Friction Welded
Aluminum to Steel Friction Weld
AWS Welding Handbook
Photomicrograph of Aluminum (top) to Steel (bottom) AWS Welding Handbook
Friction Weld Tantalum to Stainless Steel Note: mechanical mixing
AWS Welding Handbook
Continuous Drive Friction Weld of Titanium Pipe
Ti-6Al-4V-0.5Pd 246 mm diameter 14mm wall thickness No shielding used
Center
HAZ
Froes, FH, et al, “Non-Aerospace Applications of Titanium” Feb 1998, TMS
Radial friction weld of Ti-6Al-4V-0.1Ru
Properties in Weld Better than Base Metal
Froes, FH, et al, “Non-Aerospace Applications of Titanium” Feb 1998, TMS
Linear Friction Weld Repair of Fan Blades
Fan
Turbine Compressor Combustor
Walker, H, et al, “Method for Linear Friction Welding and Products made by such Method” US Patent 6,106,233 Aug 22, 2000
Friction Welding for Mounting Ti Alloy Rotor Blades
Shielding Gas & Induction Pre-heat
Weld Nub
Force
Linear Friction Weld
Schneefeld, D,et al. “Friction Welding Process for Mounting Blades of a Rotor for a Flow Machine”, US Patent 6,160,237 Dec 12, 2000
Friction Welding Connector to Imbedded Window Wires
Glass
White, D et al, “Friction Welding NonMetallics to Metallics”, US Patent 5,897,964 Apr. 27, 1999
Wire Conductor
Silver Based Ceramic Paint
Friction Stir Welding – Tool Design Modification
Hard Tool Tip Buried in Work Piece
Metal Flow
Force
Travel Speed Midling, O, et al, “Friction Stir Welding” US Patent 5,813,592 Sep. 29, 1998
Friction Stir Welding – Automation Moving Device
Elevation Platform and fixture device
Friction Stir Welder
Mobile System Ding, R. et al, “Friction Stir Weld System for Welding and Weld Repair”, US Patent 6,173,880 Jan 16, 2001
Inertia Welding
Inertia Drive
Inertia Welding Process Description • One of the work pieces is connected to a flywheel; the other is clamped in a nonrotating axial drive • The flywheel is accelerated to the welding angular velocity. • The drive is disengaged and the work pieces are brought together. • Frictional heat is produced at the interface. An axial force is applied to complete welding.
Motor Flywheel
Spindle
Non-rotating chuck Workpieces
Chuck Hydraulic cylinder
Inertia Welding 2
IS E C
E Eu A
Where E = Energy, ft-lb (J) I = Moment of Inertia, lb-ft2 ( kg-m2) S = Speed, rpm C = 5873 when the moment of inertia is in lb-ft2 C = 182.4 when the moment of inertia is in kg-m2 Eu = Unit Energy, ft-lb/in2 (J/mm2) A = Faying Surface Area
Inertia Drive
Inertia Welding Variables • • • •
Moment of inertia of the flywheel. Initial flywheel speed. Axial pressure. Forging pressure.
Linnert, Welding Metallurgy, AWS, 1994
Equipment
Inertia Welding Machine
Courtesy AWS handbook
Linnert, Welding Metallurgy, AWS, 1994
A Few Specific Examples
Super-speed (750 SFM) Inertia Welding of Jet Turbine Components Part Stator components Combustor Casing Low pressure turbine casing Other Parts
Ave. Diameter Range (in.) 10-80 42
Waspaloy
72
Waspaloy
various
Inconel Waspaloy Hastelloy Rene
Problems • Melting Destroys Properties • Low (200F) Forging Temp Range – Need Precise Control
Ablett, AM et al, “Superspeed Inertia Welding”, US Patenmt 6,138,896, Oct. 31, 2000
Super-speed (750 SFM) Inertia Welding of Jet Turbine Components Control Parameters • Workpiece Geometry (size) • Applied Weld Load Stress) • Initial Speed (surface velocity • Unit Energy Input (moment of inertia, radius of gyration) E WK 2 RPM 2 / 5873 A RPM 12SFM / D Where
E = unit energy input W = flywhel weight K = radius of gyration RPM = initial rotation SFM = speed D = diameter A = area
Ablett, AM et al, “Superspeed Inertia Welding”, US Patenmt 6,138,896, Oct. 31, 2000
Titanium Engine Valve
Inertia Weld Titanium Aluminides or Titanium Borides
Titanium Alloy (Ductile)
(Brittle at RT)
Jette, P , Sommer, A., “Titanium Engine Valve”, US Patent 5,517,956 May 21, 1996
Inertia Welding of Magnesium and Aluminum Wheels for Motor Vehicles Wheel Aluminum Mg AM60 Mg AM60 Mg AE42
Inertia Weld
Hot Inert Shielding Gas
Spider Magnesium Mg AE42 Mg AZ91 Mg AZ91
Welding parameters determined by the lower-deforming alloy or the alloy with higher melting point
Separautzki, R,et al, “Process for Manufacturing a Wheel for a Motor Vehicle” US Patent 6,152,351 Nov 28, 2000
Similarities between Continuous Drive and Inertia Drive • In both methods, welding heat is developed by frictional heat and plastic deformation. • Both methods use axial force for upsetting purpose. • In both methods the axial pressure may be changed (usually raised) at the end of rotation.
Differences between Continuous Drive and Inertia Drive
Continuous drive
Inertia drive
• One of the workpieces • One of the workpieces is directly connected to a connected to the flywheel. rotating motor drive. • Rotational speed decreases • Rotational speed remains continuously to zero during constant until the brake is the process. applied. • Kinetic energy of the • Rotational energy of the flywheel dissipates through workpiece dissipates through friction and plastic friction and plastic deformation producing heat. deformation, producing welding heat.
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