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    Friction welding: The fast, versatile joining process

    Friction welding is a joining process that allows more materials and material combinations

    to be joined than with any other welding process.

    Besides common material combinations such as steel/steel, friction welding also permits

    high-quality joining of process-critical materials such as magnesium alloys, aluminum, and

    steels with a very high carbon content or austenitic structure.

    Moreover, a whole range of different material combinations, such as steel/copper,

    steel/aluminum or aluminum/magnesium, can also be joined without difficulty.

    With friction welding, joints are possible not only between two solid materials or two

    hollow parts: solid material/hollow part combinations can also be reliably welded.

    Friction-welded parts are characterized by great accuracy in their length and eccentricity.

    The process is distinguished by very short welding times and thus extremely short

    cycle times.

    Friction welding: Process Sequence

		Phase 1: Initial situation
		§   Both workpieces securely clamped  § Rotation of one workpiece
		Phase 2: Temperature increase
		§   Workpieces brought together with force (F1)    §   Rotation (n) and forcet (F1) generate friction    §   Heating of the weld surfaces
		Phase 3: Welding
		§   Rotating workpiece is braked  §   Forging with increased force (F2)

   Friction welding: KUKA PCD process monitoring

   Constant process parameters are the essential requirement for obtaining reproducible weld

   quality. The KUKA PCD system is a control and monitoring tool for the friction welding process

   which is integrated as standard into the process controller. All quality-relevant parameters are

   monitored within freely definable tolerance limits.
 

   The parameters are entered and displayed directly at the machine. A particularly user-friendly

   feature is mouse-driven data entry. The required tolerance limits can be set or changed on the

   graphical user interface simply by clicking with the mouse.

   The current welding parameters are displayed automatically after each welding cycle. At the

   same time, the system archives all the program and actual value data.

   A further plus point is the integrated process and machine diagnosis tool. With the aid of this

  tool, any faults that occur can usually be located and corrected directly at the machine.

 

Large-scale, user-friendly screen		Detailed display		Graphical data entry interface

   A built-in modem allows the user to take advantage of all the possibilities of online customer

   support, from remote diagnosis and process analysis through to software updates.

 

   A whole world of friction welding

   Friction welding offers a wide range of potential applications - we have selected just a few

   highlights to show here:

		§   Propshaft with aluminum/steel joint
		§   Aluminum sports wheel with a double weld
		§   Trailer axle with finish-machined journals welded in defined         angular positions