Friction welding offers many benefits. One, of which, is that of consistent parts. Because RPM and Pressure are machine-controlled, the process is consistent, with only a few controlled variables. Another benefit is the narrow Heat Affected Zone (HAZ). The narrower the HAZ, the more parent material properties are retained, and the stronger the weld.
Friction Welding is a process that produces strong, consistent joints by utilizing tubes, bars, plates, discs, etc. It allows you to design complex parts that may otherwise be cost-prohibitive to create. A large diameter cylinder rod could take 20-30 minutes to weld the standard way. With Friction Welding, this could be a 5-7 minute weld. Faster cycle times mean more parts welded in less time. A definite cost savings!
One of the largest advantages is the ability to join different metals achieving 100% metal-to-metal joints, and giving parent metal properties. No additional material or fillers are required and the process is virtually emission-free. Thus better for the environment. Another advantage is cost savings when you can find substitutions for current metal products. We do need to avoid alloys that contain sulfur, lead or graphite.
The best candidates for friction welding will have one cylindrical part. Parts that have diameter changes over its length are also candidates. With the appropriate tooling, we can accommodate asymmetrical parts such as a block to a rod, and unique shapes. These parts should be parallel to each other. Sometimes instead of a solid diameter, the use of a tube will be more cost-effective by reducing the waste produced by additional machining while rendering the part to be just as strong.
