Traditionally, welding is known as a fabrication process that joins materials by causing fusion. While many methods of welding involve an energy source such as a gas flame, electric arc or a laser; Friction Welding does not. Friction Welding is actually a forging technique. It involves generating heat with relative motion and high force. The result is friction between two materials, generating heat to soften them and join them together.
TYPES OF FRICTION WELDING
Friction Welding takes many different forms. MTI offers the four most in-demand — all of which are solid state processes:
- Rotary Friction Welding —in which one part is rotated at high speed and is pressed against another part that is held stationary.
- Low Force Friction Welding —in which an external energy source is used to raise the interface temperature of the two parts being joined, thereby reducing the process forces required to make a solid-state weld.
- Linear Friction Welding —in which one part moves in a linear motion at high speed and is pressed against another part held stationary.
- Friction Stir Welding — uses a spinning tool and axial forge force to create a bond between two pieces, which creates extremely high-quality, high-strength joints with low distortion. MTI offers Friction Stir Welding development and part production through our Manufacturing Services.
BENEFITS OF FRICTION WELDING
As a solid state joining and welding solution, the Friction Welding process helps companies make smart business decisions because it offers a number of advantages, including:
1. Highly Durable Welds
Bonds are seamless in their solid state, which means they're designed to hold up in tough circumstances where traditional welding may fail. Increased bond strength means longer lasting parts, and that affects the ultimate bottom line.
2. Reduced Manufacturing Costs
Due to the versatility of Friction Welding, companies can join two pieces together, many times less expensively than starting with a one-piece forging. No consumable materials are used, and preparation processes are minimized due to the efficiencies Friction Welding brings to the table.
3. Reduced Weight for Numerous Applications
Friction Welding produces lighter finished products, making it a great solution for many tough engineering challenges. That's because it allows for dissimilar materials to be joined together – including many combinations that are otherwise considered unweldable.
Friction Welding can be used for a variety of part geometries and applications including jet engine bladed disks (blisks), automotive air bag components, retail bar bells, military vehicle components, and pistons or axles to name a few.
At MTI, we develop customized Friction Welding process solutions for customers in many different industries and countries. Doing so has helped us become the global leader in Friction Welding solutions. We have over 800 friction welders on six continents, purchased by satisfied customers including research centers dedicated to the promotion and development of innovative uses of Friction Welding. MTI continues to be at the forefront on how to use force and motion for advances in manufacturing.
We also provide on-site manufacturing welding services from our headquarters in South Bend, Indiana, our location in Kingswinford, England, and our most recent location in Pune, India from FWT. Our locations are also global service centers, as is our facility in Shanghai, China.
FIND YOUR SOLUTION
MTI serves a variety of industries and applies Friction Welding to thousands of applications including global aerospace companies, the U.S. military, large agricultural and trucking companies, and more! And we're prepared to find a solution for your needs. We’ll build a machine that makes your part, we’ll make the part for you, or we’ll help you make the part even better.
Curious to know if Friction Welding can optimize your process? Contact us to start the conversation!