Friction Welding Machines
Automated Welding Systems for Electric Vehicle Parts, Batteries, Shafts, and Drill Pipes
LPR Global’s rotary friction welding machines minimize material loss and burr for automotive manufacturers by precisely controlling joining time, weld length and forging force.
Common applications include:
- Joining e-mobility components such as EV battery terminals and motor shafts
- Producing automotive parts such as camshafts, pistons, propeller shafts, engine valves, shock absorber rods, torque converters, and rear axle housings
We also provide CNC friction welding machines and hydraulic servo-driven machines to manufacturers in the oil and gas industry that produce drilling pipes and frac balls.
Our automated machines are manufactured in South Korea, and machine installation and aftersales support are provided by local engineers wherever our clients are.
Rotary Friction Welding Machines for Electric Components
We provide fully automated friction welding lines with robot arms and poka-yoke capabilities for mass production of e-mobility components, camshafts, pistons, propeller shafts, engine valves, shock absorber rods, torque converters, and rear axle housings. Our machines are equipped with patented hydraulic chucks, steel bar structures, friction welding apparatus, and power steering main shaft mechanics. Automated features allow for easy operation with minimal training.
What sets us apart?
- Our machine designs are backed by multiple technology patents for welding alloys and mechanical structures that offer superior precision and control when joining dissimilar metals.
- Stable workpiece grip and consistent shaft centricity throughout the welding process, thanks to our mechanical structure technology present in the friction welding apparatus, hydraulic chucks, and power steering main shaft mechanics.
We provide CNC friction welding machines and hydraulic servo friction welding machines with automated features for easy operation. Our machines are equipped with patented hydraulic chucks, steel bar structures, friction welding apparatus, and power steering main shaft mechanics.
|Model 8SF||Preferred by camshaft manufacturers in the automotive industry. Features 8-ton forging force for single-sided friction welding.|
|Model 100SF||Used by track roller manufacturers in the heavy industrial equipment industry.|
|Model 12DF||CNC-controlled machine with high precision and short cycle times, preferred by propeller and drive shaft manufacturers|
Machine configurations can be customized to your needs. See our full product range in the Rotary Friction Welding Machine brochure.
- Automated loading and unloading conveyor system
- Contact-based or non-contact based inspection systems for the feeding conveyor – preferred by clients who arrange NG parts before friction welding
- Torque converters
- Propeller shafts
- Intermediate shafts
- Drive shafts
- Universal joints
- Constant velocity joints
- Engine valves
- Engine pistons
- Compressor pistons
Axle and Brake Components
- Rear axle shafts
- Brake pistons
- Yoke shafts
- Rear axle housings
- Torque rods
Suspension and Steering Components
- Shock absorber rods
- Push rods
- Motor shafts
Machine Parts and Structural Components
- Print rollers
- Ball screws
- Gear shafts
- Steel balls
- T-shaped bars for gravity-based LNG terminals
- Drill pipes
- Valve bodies
- Shower heads
- Aluminum blanks for frac balls
Construction Machine Parts
- Torque converters
- Hydraulic piston rods
- Hydraulic pump pistons
- Track rollers and roller bushings
- Electrical cable connectors
- Battery cables
- Bus bars
Hydraulic Friction Welding Machines
- Shortened welding cycle time and increased efficiency
- Easy, user-friendly operation with minimal training required
- Automated welding system reduces human effort
- Minimal preparation required on welding materials
- Low energy consumption
Hydraulic Rotary Friction Welding Machines
Welding cycle graphics (Touch screen PC)
|Nominal Forge Load|
|Typical Spindle Power|
|Max Spindle Speed|
|Max Weld Area |
CNC Friction Welding Machines
- Reduce setup time with automatic servo-driven length adjustments
- Reduce cycle time with precise servo-controlled speed
- Increase operational stability by reducing fluctuations in oil temperature
CNC Friction Welding Machines
Welding cycle graphics (Touch screen PC)
CNC SF (Single Spindle)
CNC DF (Double Spindle)
Friction Welding Process and Advantages
How does Friction Welding work?
Friction Welding uses friction heat to create a plastic zone between workpieces, which are then forged together with external force. The entire workpiece interface is welded simultaneously, which eliminates offset typically caused by thermally induced stresses. The friction welding process also provides consistent, repeatable quality in which the welded piece has minimal burr or flash because of precise machine-controlled forging force.
Any forgeable material can be friction welded. This includes a wide range of metals, non-metals, and formed products such as castings or powder-metal parts. In cases where forged parts are replaced with sintered or powder metal pressed parts to reduce manufacturing costs, friction welding technology is used to weld partly forged material and powder pressed material together.
Friction Welded Pipe, Bar, and Plate Interfaces
Bar + Bar
Bar + Bar
Optimal shape in the welding zone considering the heat balance
Pipe + Bar
Pipe + Bar
Joining method that best conceals or removes flash
Pipe + Pipe
Pipe + Plate
Bar and Plate
Advantages of Friction Welding
Can be used to join dissimilar metals
- Steel + Stainless steel
- Steel + Powder metal
- Cu, Al + Stainless steel
Can be used to join non-ferrous metals
- Al + Cu
- Al + Al or Cu + Cu
Reduces material costs & forging costs
- Can replace non-critical parts with less costly materials using friction welding
- Can replace full forging with partial forging and friction welded components
Reduces weight of parts
- For example, forged bars can be replaced with tubes
Streamlines manufacturing processes
- For example, gundrilling can be replaced with friction welding pipes to bars
Eliminates need for leak inspection
- Increased air tightness at joints makes them leak-proof
Rotary Friction Welding Machine Options
- Displays important parameters
- Data from every weld is stored and easily retrieved
- Machine status and diagnostics
- Welding parameter database
- Record of each welding cycle
- Alarm conditions
- Applicable to cylindrical shaped workpieces (1-and 2-axis NC)
- I.D. or O.D. flash can be sheared off directly
- Applicable to non-cylindrical shaped workpieces
- Mechanically or electronically controlled angles on both ends of the product after welding when specific angles are required, such as with propeller shafts
- Reduce cycle time via precisely controlled speed using servo motors
Rotary Friction Welding Machine Video
Business Case: Friction Welding for Oil & Gas Ball Drop System Supplier for Fracturing Ball Manufacturing
A Texas-based global oil & gas ball fracturing system manufacturer for oil and gas wells found single headed rotary friction welding machine model 50SF as an answer to its need to weld 2024-T351 aluminum blanks with a wide range of lengths up to a maximum of 5,000 ㎟ welding area. Their aluminum balls that used to be machined from solid blanks are now made by friction welding two aluminum blanks with hollow space inside, and then machined for use as fracturing balls in wells.
This client provides drilling pipe solutions and oil fracturing system for technically challenging applications in open wells in the oil and gas industry. When we worked with this oil fracturing system manufacturer, they were familiar with the advantages of friction welding over other conventional welding methods, as well as the friction welding technology, and wanted to replace their existing manufacturing method with friction welding technology.
Being suggested model 50SF, a hydraulic single headed friction welding head machine, they sent us their aluminum blank samples for test welding which were sent back for quality tests post friction welding. The client conducted their own testing on the welded samples for any mismatch of axis measurements at weld, tensile strengths, and bend tests. After reviewing the test results, they visited our manufacturing site in Korea and signed off to have their own Model 50SF manufactured because it has the capability to handle wider range of blank lengths than competitors and to reduce the loss of aluminum blanks with more precise control.
Rotary friction welding machine model 50SF has a welding precision of 0.5mm length between datum faces, and 0.15mm mismatch of axes at weld. This friction welding machine is equipped with robust 2-axis in-machine flash removal; welding process is shortened this way instead of moving the welding piece to a flash removal station. In addition it is equipped with 2 jaw chuck at the fixed axis and spindle head. Our welding operating system has a touch panel with industrial PC where all the operating information is communicated with the PLC and saved into the PC; it also allows engineers to easily make changes in the welding parameters for customization. Operator can view the real-time display of friction pressure, forged pressure, RPM, and part length value.
All of our rotary friction welding machines are customized to each client’s welding needs. Please contact us for your own friction welding machine specification.
Business Case: Friction Welding for Automotive Shock Absorber Manufacturer
A global-sized shock absorber rod manufacturer selected our CNC double headed rotary friction welding machine for their steel double welded shock absorber rod production plant when they needed to increase their production size with reduced cycle time and reduced material costs to meet their growing client base and orders.
This client was looking to add a fully automated rotary friction welding line with an automatic loading and unloading function, flash removal feature, and poka-yoke capabilities post welding at its mass production plant in Europe. Their limited floor space at the plant allowed only a well-integrated automatic friction welding line; the line designer had to be equipped with not only the knowledge about the friction welding technology but also a deep understanding of the client’s manufacturing process at the plant, in the automotive industry.
Our friction welding solution for this client was a CNC controlled double sided rotary friction welding machine that welds two end stems to a S45C steel tube at each end simultaneously at maximum 12 tons of forging force. Maximum weldable area was 800㎟ with tube thickness range of 1-6mm. Shearing unit was attached to the line to allow automatic shearing of the flash post welding, and cycle time was kept at maximum 12 seconds. The welding system was designed to check and monitor the friction force, forge force, total upset amount, main axis RPM, length of the weld, and the friction time for quality control of the welded joint from start to finish. The break for the spindle was designed to stop within 0.5 seconds along with other hydraulic parts to precisely control the weld time, rotation speed, and forge force.
The client’s need for the automatic integrated line provided us with the opportunity to demonstrate our core strength: rich experience and understanding about the automotive industry. From our total clientele base, over 75% are from the automotive industry. Our line design was submitted and approved within a short period of time and the client knew that their friction welding line was being built by a team familiar with automotive manufacturing processes. This client will be equipping the plant with more of these machines to continue supporting their production capacity growth.
We build fully automated friction welding lines for clients’ specific needs.
Business Case: Single Headed Friction Welding Machine for T-bars
Welding T-bars for LNG Gravity Based Structures
HYD 15SF, a horizontal type single headed hydraulic friction welding machine was designed and manufactured for LNG producer wishing to manufacture T-bars required for structural support of LNG gravity based structures. To create a high strength bond between reinforcement bars (rebars) and end plates to create T-bars that can withstand bending force, and the weight of concrete, our client looked into friction welding to join the two parts.
HYD 15SF was designed to friction weld EN 10025-2 grade G450J0 end plates to S450J0 reinforcement bars with up to maximum weld area of 1000mm² with maximum welding force of 15 ton under total cycle time of 40 seconds with automatic loading and unloading.
Our recent T-bar manufacturer’s requirement was to be able to weld reinforcement bars between diameter of 15mm-32mm to end plates of various sizes (see specification below). The welded T-bars had specific welding quality requirements that included perpendicularity of 3˚, and eccentricity tolerance of 3mm. Welding joint had to maintain its connection at design temperature as low as -60˚C.
Tensile test was required in regular temperature condition, and at low temperature -60˚C. It required the weldments to be tested without flash removal, and fracture had to be observed in the reinforcement bar parent material at minimum 1 bar diameter away from its welded connection. (e.g. 32mm diameter rebar requires fracture to be seen at a minimum 32mm above the welded connection). No partial or total fracture in the T-plate or in the welded connection was allowed.
Bending test required the specimens to be bent without fracture at a 90˚ angle with minor tearing accepted. Hardness of HV5 or 375 was required using a Vickers hardness survey of the weldment’s
End plates dimensions: Width 30mm-110mm / Length 60mm to 110mm / Thickness 14mm to 25mm
Reinforcement bars: Diameter 15mm- 32mm.
Business Case: Rotary Friction Welding Machine for Torque Converters
Welding Torque Converters for Automotive Powertrain
A CNC controlled friction welding machine CNC 10SFV was developed for our global automotive tier 1 client focusing in powertrain, and thermal systems. CNC 10SFV model friction welds torque converter’s hub and housing vertically.
This vertical rotary friction welding machine maintains cycle time of 36 seconds and a precision level of TIR 0.3mm with fully automated welding process including automatic loading and unloading function and a flash removal unit. This machine friction welds and instantly forges using the generated heat for maximum welding area of 600㎟ and maximum forge force of 10 tons based on the materials and dimension of the torque converters.
Tooling including the jigs are also designed and manufactured in-house to allow one model of friction welding machine for welding different models of torque converters.
Our friction welding machines can be used to friction weld other Powertrain components including:
- Propeller Shafts
- Intermediate Shafts
- Constant Velocity Joints