The friction welding process is a mechanical welding method that allows the assembly of two metal pieces in a plastic state. This technique involves generating friction through the linear or rotational movement of one piece or tool against one or more other pieces. This friction produces intense heat at the interface of the two pieces, softening the metal until it becomes plastic. Then, by applying force and maintaining this pressure, the pieces deform and fit perfectly until they are welded together during the cooling process. There are different types of friction welding.
In rotary friction welding processes, two pieces are held facing each other. One of the pieces is in rotation while the other remains stationary. Several variations exist depending on how the rotating piece is driven. Once the pre-determined rotation speed is reached, pressure is applied to bring the pieces into contact and assemble them. It is the combination of compression force and high rotation speed that causes self-heating and welding to occur.
In the inertia friction welding variant, the piece is fixed to an inertia flywheel to store the kinetic energy provided by the machine. Once the predetermined rotation speed is reached, the piece is released and continues to rotate due to inertia.
Inertia friction welding
In direct drive friction welding, the piece is rotated or translated directly by the machine. The variation of torque and motor speed enables welding.
Evolution of temperature during the direct drive friction process
In linear friction welding, the first piece remains fixed while the second executes small back-and-forth movements. Similar to friction stir welding, this movement generates friction, thus increasing the temperature of the materials. Applying force ensures the formation of the welded joint.
Evolution of temperature during the linear friction welding process
Friction stir spot welding involves assembling two pieces arranged to be glued together and held by a clamping system. A specific tool creates a mixing point by friction: the pin (lower part of the tool) increases the temperature of the metal until it becomes plastic, allowing it to be mixed and welded, while the shoulder (upper part) keeps the metal in a plastic state and prevents it from flowing out. Once the mixing point is achieved, the tool is lifted, and the piece can be removed or moved.
Evolution of temperature during the friction stir spot welding process
Due to these advantages, friction welding is increasingly used in various industries such as automotive, aerospace, naval, and space, especially for manufacturing lightweight components.
Numerical simulation offers numerous advantages regarding your welding process, allowing you to predict the behavior and thermomechanical properties of your assembly. With our software, you can:
Using predictive simulation, you can gain in-depth insight into your welding process, forecast results, and optimize parameters to achieve high-quality assemblies. This saves time and reduces costs associated with physical testing while improving the reliability and performance of your welds.
With all these features, TRANSWELD® offers a comprehensive environment for simulating friction welding accurately and efficiently, thus optimizing the process and obtaining high-quality assemblies.