Overview

Principles of Friction welding

It has been known very well that rubbing one object against another generates heat. Friction joining method is one of applied techniques, which join two pieces of metal by means of the frictional heat, known from primitive age.

With the friction joining method, a pair of base metals are touched, pressed and turned in opposite directions each other, in order to generate heat on the contacting faces. The heat thus generated softens the contacting faces and periphery. When it reaches the friction joining temperature, the relative movement of metals is stopped. As the thrust force for pressure joining is increased in this condition, the pair of metals is joined by the van der Waals forces.

Van der Waals forces

1

Inter-atomic distance of two base materials, whose deformation resistance has been reduced due to softening caused by friction heat, narrows.


2 Bonding completes when the point B, where the attractive force, which is force that the atoms of the base material surfaces pull toward each other upon contact, is drawn to the point I, where the attractive force comes to equilibrium with the repulsive force.

3 Therefore, formation of the equilibrium becomes possible at the temperature less than or equal to the melting point of the metal.

4 Even when welding dissimilar metals, two metals are bonded if an equilibrium is reached between its attractive force and repulsive force.

Fingertips of gecko
 

The reason why geckos were exhibited at the British House in Expo 2005 Aichi Japan was because an enterprise of U. K. had been developing a gadget called "Gecko Tape" which enables to move freely on a ceiling or wall like the reptile.

This item is looked forward to earnestly because, should it be materialized, it will extend the degree of freedom for astronauts in walking around freely in weightless outer space without tethers.

Geckos can move around on the wall or ceiling just like on the floor. They must have spectacular suckers on their feet, you may imagine. On the contrary, there are no suckers on their soles, but they show striped patterns only instead.

These striped patterns are, in fact, covered densely with fine hairs, in extent of a few hundreds of million hairs per square centimeter. Moreover, the tip of each hair is branched and so the gecko's feet are touching the wall or ceiling with an innumerable number of hairs.

Why they can move around freely on the wall or ceiling using them?

In fact, the hairs on the feet of gecko are extremely fine, which mean they contact at a great number of minute points on the wall so that the molecules constituting a hair and those of wall pull each other, or, in other words, the intermolecular forces work between them.

By the way, the intermolecular force is working also in the phenomenon that a pair of plate glasses are stuck firmly each other.

The "Gecko Tape" also is attempting to use the intermolecular force. Contrary to suckers, which are useless in air-less condition, the intermolecular force is looked forward to earnestly because it works perfectly even in outer space where there is no air.

Friction welding cycle

Refer to the friction joining cycle.  
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Features of friction welding machine

(1) Improves Quality

  • Completely defect-free. No worry over blowholes.
  • Highly reproducible. Provides stable joints.
  • Low thermal strain and high dimensional precision.

(2) Reduces Costs

  • Pre-welding processes, such as grooving and spigot making, not required
  • Possible to weld dissimilar metals or non-ferrous metals together.
  • Low energy consumption: 1/5 1/20 compared to other welding methods.

(3) Improves Production Efficiency

  • Easy operation. Special skill not required.
  • Equipped auto-loader realizes unmanned operation.
  • Friction Welding Machine is renowned for its durability.

(4) Improves the Environment

  • Prevent Global warming: Carbon dioxide emissions reduced by half.
  • People- and environmentally-friendly with no generation of sparks and gases.


CO2?????

  Before After
Conversion to friction welding CO2 arc welding
Comparison of electric energy per joint
Hydraulic type FW, CO2 of electricity
Emission coefficient: 0.12
(Promoting Household Eco-account Books issued by the Japan Environmental Agency (present Ministry of the Environment)
CO2 consumption (m2) 0.0162 0 47% reduction
Electricity usage
(kWh)
0.1583 0.1543
CO2 emissions(kg ) 0.0352 0.0185
Employment of NC on friction joining machine ydraulic F
Comparison of electric energy per cycle
NC type FW

Power consumption(kWh) 0.14 0.10 29% reduction
CO2 emission(kg ) 0.0168 0.0120

Total CO2 emission is reduced to approx. 1/3. [Prevention of global warming]


 

Combination of materials

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Please contact the following for inquiry concerning the friction joining:
Inquiry contact

 

History of the friction joining method

1954

A. I. Chudikov of U.S.S.R. succeeded in the experiment of friction welding, using a modified lathe and round metal bars. VNIIESO (U.S.S.R. Electric Welding Machine Research Institute) took up the idea and started the research and development from around 1956.

1957

The Institute developed and made public the friction welding machine MST-1. After this announcement, many countries started research and development of the technology for practical applications.

1958

Development in U.S.S.R. entered the stage that the technology was introduced in the production processes.

1958

BWRA (British Welding Research Association) succeeded to produce a prototype of friction welding machine. AMF Corp. of the U.S. also publicized a prototype in the same year.

1960

A work "Friction joining of metals" by VILL of VNIIESO was introduced as a research data in Japan. This triggered ardent investigations and researches on the friction joining.

1960

A machine tool research group brought back useful information from the USSR.

1962

Toyota Industries Corp. developed initially in the country a brake type friction welding machine as mass production equipment.

1964

The Friction Joining Research Conference was founded. It was renamed later as the Society for the Study of Friction Joining and further to the Friction Joining Association, which continues activities to this day.

1973

Izumi started the consignment production of friction welding machines under an agreement with Toyota Industries Corp.

1994

JIS 3607 Standard for the friction joining work of carbon steel was enacted.

1997

Izumi succeeded the whole of the friction welding machine developed by Toyota Industries Corp.

1998

Developed an NC controlled phase adjustment friction welding machine for practical applications

2002

Developed a super fine diameter (for ?1.6) friction welding machine for practical applications (applicable to drill, sensor shaft, etc).


Access the Web site of Japan Friction Joining Association from:


Japan Friction Joining Association
(Japanese language)