Advances in friction welding process: A review

Abstract

Friction welding is now well established as one of the most economical and highly productive methods in joining similar and dissimilar metals. It is widely used in automotive and aerospace industrial applications. Friction welding is often the only viable alternative in this field to overcome the difficulties encountered in joining the materials with widely varying physical characteristics. This process employs a machine that is designed to convert mechanical energy into heat at the joint to weld using relative movement between workpieces, without the use of electrical energy or heat from other sources. This review deals with the fundamental understanding of the process. The focus is on the mechanism of friction welding, types of relative motions of the process, influence of parameters, heat generation in the process, understanding the deformation, microstructure and the properties of similar and dissimilar welded materials.

Natural Aging Behavior Of Friction Stir Welded Al-Zn-Mg-Cu Aluminum Alloys

“…Though FSW basics have been previously described in a few review papers, e.g. [1][2][3][4][5], some issues regarding the process-microstructure-properties relationship remain unclear and require further research. Even though it has been already found that high-quality, sound welds with good mechanical properties may be produced between non-weldable aluminum alloys of the 7000 series [6,7], the phenomena occurring spontaneously after welding (natural aging) in these alloys need further explanation.…”

3D modelling of Ti–6Al–4V linear friction welds

“…LFW works by oscillating one workpiece relative to another while under a compressive force [9][10][11][12]. Although a continuous process, Vairis and Frost [10] noticed that LFW occurs over four unique phases:…”

Joining of dissimilar materials

“…This causes the HAZ to have non-uniform thicknesses and also the possibility for IMC when welding dissimilar metals. These shortcomings are addressed by orbital welding [254] though very limited research work has been published on this. An inherent advantage of friction welding is significantly lower operating temperatures.…”

“…Uday et al [254] completed a well-documented review of the types and mechanisms of friction welding and resulting microstructure and properties of both similar and dissimilar material joints. Three important process parameters have been shown to impact bonding: speed, pressure, and time [121,132,254].…”

“…Three important process parameters have been shown to impact bonding: speed, pressure, and time [121,132,254]. Heating time is typically minimized to reduce waste and overall IMC layer thickness [107].…”