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Rotary Friction Welding Machine Quality Depends On Fixture Design Capability
Jan 24, 2024
Friction welding is widely adopted in many industries for its fast speed and minimal material loss. Two types of friction welding machines are available in the market: stir friction welding and rotary friction welding. Common myths about rotary friction welding include that it can only be used with cylindrical pieces, with certain materials, and with the help of a skilled operator. In this article, we debunk these myths and explain the versatility and user-friendliness of our rotary friction welding machines.
Myth #1: Rotary friction welding can only be used with cylindrical workpieces
Rotary friction welding is widely used by manufacturers of automotive parts, EV battery terminals, shafts for construction equipment, machine engine components, and frac balls for oil and gas drilling, among others. These parts do not need to be cylindrical, as is sometimes falsely believed. As long as one of the two products being welded together is cylindrical, the other product can be of any shape.
This is where chuck or fixture design capabilities become critical, when choosing a supplier for rotary friction welding machines. If the machine manufacturer is not a skilled chuck or fixture designer, the machine won’t be able to hold the product steady and control the centricity of the welded product
Below are some products made by our rotary friction welding machines:
Myth #2: Rotary friction welding can only be used with certain materials
The friction welding process involves solid-stated joining of two materials with dissimilar or similar properties. Beginners to friction welding often believe that the technology can only be applied to materials that are resistant to high temperatures. This is not the case – our machines weld together aluminum and copper for battery terminals, neither of which are high temperature-resistant.
However, it is true that the rotary friction welding machine will not perform as expected, unless the machine manufacturer has experience with a wide range of applications and materials. This is important in order to calculate the melting point of each material and the thrust forging force. The calculation is also based on the material thickness, welded surface space and, to make the matter more complicated, the depth of the joined zone, defined by the client. Without experience with diverse materials, it is challenging for the machine manufacturer to calculate the forging force, and rotational speed and time of the welding shaft.
When choosing a rotary friction welding machine, pay attention to how many machines the manufacturer has built previously, and to which industries. We are the global leader in the automotive industry – many tier 1 automotive part and battery manufacturers use our friction welding machines in their mass production lines.
Myth #3: Rotary friction welding requires a skilled operator
Any high-end rotary friction welding machine is fully automated, and does not require a skilled operator. As long as they can press a button on the Operator Panel, the machine can operate itself from start to finish for the entire welding process.
As a manufacturer of automated friction welding machines, we believe automation is important in limiting human error and interference with the machine’s movement and process. Some of our machines require no operator at all, as we have even automated the processes of loading products to the machine and unloading welded products to a designated location.
In summary, rotary friction welding machines can be used with many workpiece shapes, provided one workpiece is cylindrical, with various materials, whether they are temperature-resistant or not, and without the need for a skilled operator.
When selecting the best friction welding machine manufacturer for your application, make sure to evaluate the following aspects of the manufacturer:
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- Fixture or chuck design capabilities
- Material knowledge and experience with building friction welding machines for various applications
- Automation expertise
Please visit our rotary friction welding machine page to learn more about our machine specifications for different applications, and patented technology of our chuck and shaft design. If you would like to speak with a specialist, please contact us.