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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. [ 1 ]
Example of friction welding with flywheel. In inertia friction welding the drive motor is disengaged, and the workpieces are forced together by a friction welding force. The kinetic energy stored in the rotating flywheel is dissipated as heat at the weld interface as the flywheel speed decreases.
Inertia welding machines use a motor to spin the parts to a set RPM, and then disengages the motor and relies on the internal friction of the parts to slow down the machine again. The inertial energy contained in the machine's flywheel is transferred to the weld interface through the parts.
The oldest welding process in the world. Oxides must be removed by flux or flames. Damascus steel: Friction welding: 42: FRW Thin heat affected zone, oxides disrupted by friction, needs sufficient pressure Aerospace industry, railway, land transport Friction stir welding: 43: FSW A rotating non-consumable tool is traversed along the joint line
Inertia friction welding is the traditional proven method. Direct drive friction welding is controlled and monitored up to 1,000 times a second, resulting in a fine quality weld that does not necessarily need a full heat treat quench and temper regime.
Dissimilar friction stir welding (DFSW) is the application of friction stir welding (FSW), invented in The Welding Institute (TWI) in 1991, [1] to join different base metals including aluminum, copper, steel, titanium, magnesium and other materials. [2] It is based on solid state welding that means there is no melting.
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