Friction Welding Machines

Rotary friction welding machines for electric vehicle batteries, camshafts, and pistons in the automotive industry and drill pipes for the oil and gas industry

LPR’s friction welding machines feature patented technology, such as hydraulic chuck structure, steel bar structure, friction welding apparatus, and power steering main shaft mechanics. Our product line includes CNC, servo, and hydraulic friction welding machines.

 

Our friction welding technologies are widely used by drilling pipe manufacturers in the oil and gas industry and automotive part manufacturers for camshafts, pistons, propeller shafts, engine valves, shock absorber rods, torque converters, and rear axle housings. LPR’s tubular friction welding solutions provide precise control over the joining time and forging force to minimize loss of your materials.

 

All of our friction welding machines are manufactured in South Korea. Machine installation and aftersales support are provided locally in USA and Canada for North American clients.

 

Contact us with your friction welding needs and projects.

Rotary Friction Welding Process | CNC and Hydraulic Friction Welding Machines

 

The rotary friction welding machine is designed and built by U-Jin Tech, a leading manufacturer in the friction welding market in Korea who holds multiple patents on magnesium alloy welding technology and on mechanical structures, such as the friction welding apparatus, hydraulic chucks, and power steering main shaft mechanics.

 

We offer 2 types of rotary friction welding machine line: CNC rotary friction welding machine or hydraulic friction welding machines, depending on clients’ preferences. Our rotary friction welding machines can also be fully automated, including automatic loading and unloading with a robot arm, and poka-yoke capabilities by measuring and monitoring the friction welded tube lengths during the process, which is the ideal friction welding solution for mass production factories.
Our clientele use our friction welding machines for the applications below:

 

Electric vehicle batteries, cam shafts, pistons, propeller shafts, drive shafts, intermediate shafts, inflators, copper rollers, track rollers, electrical connectors, drilling pipes.

 

pdf-iconFriction Welding Machine for Automotive Parts

 

Our model 8SF is the preferred choice for camshaft manufacturers in the automotive industry; model 100SF is widely used by track roller manufacturers in the heavy industrial equipment industry; our CNC 12DF is a favorite among propeller and drive shaft manufacturers. Please see our product line in the brochure, or check out the Hydraulic Friction Welding Machines and the CNC Friction Welding Machines on this page. We offer customized options for various clients’ specific needs.

Rotary-Friction-Welding-Process | friction welding machine
rotary friction welding process | friction welding machine

Friction Welding Combinations

 

Friction welding solves design challenges because friction heat creates a plastic zone between two work pieces where they can be forged together under external force. The complete interface is welded simultaneously, which creates no offset thermally induced stresses and provides consistent, repeatable quality because the process is completely machine-controlled.

Welding Interface and Design 

Bar + Bar

bar and bar | rotary friction welding

Bar + Bar

bar and bar | rotary friction welding combination

Considering the shape of the heat balance

shape of heat balance in rotary friction welding

Pipe + Bar

rotary friction welding pipe to bar

Pipe + Bar

pipe and bar | rotary friction welding

Detail showing method of upset concealment

detail showing method of upset concealment | rotary friction welding

Pipe + Pipe

Rotary friction welding pipe to pipe

Pipe + Plate

pipe and plate | rotary friction welding combination

Bar and Plate

bar and plate | rotary friction welding

Any forge-able material can be friction welded; this includes a wide range of metals, non-metals, and formed products such as castings or powder-metal parts. Many automotive part manufacturers reduce their manufacturing costs by replacing forged parts with sintered or powder metal pressed parts, in which case friction welding technology is used to weld partly forged material and powder pressed material together.

Friction Welding Combination Examples

friction welding dissimilar metals | rotary friction welding

Dissimilar metals can be joined

  • Steel + Stainless steel
  • Steel + Powder metal
  • Cu, Al + Stainless steel
Friction Welding Non Ferrous Metals | Rotary Friction Welding

Non ferrous metal can be joined

  • Al + Cu
  • Al + Al or Cu + Cu

Hydraulic Friction Welding Machines

Hydraulic Rotary Friction Welding Machine

Hydraulic Rotary Friction Welding Machines

Process Monitoring | PC monitoring | rotary friction welding

Welding cycle graphics (Touch screen PC)

Improve Productivity

  • Shorten welding cycle time and increase efficiency
  • Minimize human errors with a simple, easy to use design
  • Automated welding allows for redeployment of skilled labor
Technical Data 
8SF/DF
15SF/DF
30SF/DF
60SF/DF
100SF/DF
125SF/DF
Nominal Forge Load
ton
8
15
30
60
100
125
Typical Spindle Power
kW
17.5
22
37.5
55
90
112
Max Spindle Speed
rpm
3,000
2,500
2,000
1,300
1,000
1,000
Range Weldable
(Mild Steel)
mm
4~28
8~38
20~50
25~80
45~100
50~125
Max Weld Area
(Mild Steel)
mm^2
600
1,100
2,000
5,000
7,850
11,500
Hydraulic SF (Single Spindle)
DF (Double Spindle)
DF (Double Spindle)
 
Model
Spindle Speed
Max. Forging Force
Max. Solid Diameter
Max. Weld Area
Spindle Drive Motor
Friction Welding Machine with Forging Force of 8 tons for camshafts and engine valves
Friction Welding Machine with Forging Force of 8 tons for camshafts and engine valves
8 SF
1,700 rpm
8 Ton
Ø 28 mm
600 ㎟
17.5kW
Friction Welding Machine with Forging Force of 10 tons for Electrical Connectors
Friction Welding Machine with Forging Force of 10 tons for Electrical Connectors
10 SF
2,700 rpm
10 Ton
Ø 32 mm
800 ㎟
17.5kW
Friction Welding Machine with Forging Force of 10 tons for piston rods
Friction Welding Machine with Forging Force of 10 tons for piston rods
10 DF
2,000 rpm
10 Ton
Ø 32 mm
800 ㎟
30kW
Friction Welding Machine with Forging Force of 15 tons for Propeller Shafts
Friction Welding Machine with Forging Force of 15 tons of 15 tons for Propeller Shafts
15 DF
2,300 rpm
15 Ton
Ø 60 mm
1,100 ㎟
60kW
Friction Welding Machine with Forging Force of 50 tons for Aluminum blanks for fracturing balls
Friction Welding Machine with Forging Force of 50 tons for Aluminum blanks for fracturing balls
50SF
1,500 rpm
50Ton
Ø 100mm
4,000 ㎟
90kW
Friction Welding Machine with Forging Force of 60 tons for Steering Rack Shafts
Friction Welding Machine with Forging Force of 60 tons for Steering Rack Shafts
60 DF
1,500 rpm
60 Ton
Ø 145 mm
5,000 ㎟
83kW
Friction Welding Machine with Forging Force of 60 tons for Drill Pipes
Friction Welding Machine with Forging Force of 60 tons for Drill Pipes
60 DF
1,500 rpm
60 Ton
Ø 145 mm
5,000 ㎟
83kW
Friction Welding Machine with Forging Force of 100 tons for Track Rollers
Friction Welding Machine with Forging Force of 100 tons for Track Rollers
100 SF
1,000 rpm
100 Ton
Ø 180 mm
7,850 ㎟
108kW

CNC Friction Welding Machines | Precise Angle Control

CNC Rotary Friction Welding Machines

CNC Friction Welding Machines

Welding cycle graphics (Touch screen PC)

Welding cycle graphics (Touch screen PC)

Improve Productivity

  • Reduce cycle time due to precisely controlled speed using servo motors
  • Increase operational stability by reducing fluctuations in oil temperature
  • Reduce the setup time by using a servo that automatically adjusting to the length of the material

 

Technical Data
CNC 5 SF/DF
CNC 8 SF/DF
CNC 12 SF/DF
CNC 22 SF/DF
Nominal Forge Load (ton)
5
8
12
22
Nominal Forge Pressure (kN)
50
80
120
220
Stop Angle Accuracy
±0.5°
Mild Steel Weldable Range (mm)
6~20
8~25
10~32
15~45
Spindle Rotation (rpm)
3,000
2,500
2,000
2,000
Spindle Stroke (mm)
250
300
300
400
Mild Steel Max Weld Area
(㎟)
350
500
800
1,500
CNC SF (Single Spindle) | Rotary Friction Welding

CNC SF (Single Spindle)

CNC DF (Double Spindle) | Rotary Friction Welding

CNC DF (Double Spindle)

 
Model
Spindle Speed
Max. Forging Force
Max. Solid Diameter
Max. Weld Area
Spindle Drive Motor
CNC Friction Welding Machines for Shock Absorber 8DF
CNC Friction Welding Machines for Shock Absorber
CNC 8DF – 2 Axis Flash Removal
2,000 rpm
8 Ton
Ø 28 mm
500 ㎟
38.5kW
CNC Friction Welding Machines for Drive Shafts 12DF
CNC Friction Welding Machines for Drive Shafts
CNC 12DF – Dual Axis Flash Removal
2,000 rpm
12 Ton
Ø 80 mm
800 ㎟
60kW
CNC Friction Welding Machine with 12 Ton Forging Force for Propeller Shafts
CNC Friction Welding Machine with 12 Ton Forging Force for Propeller Shafts
CNC 12DF
1,800 rpm
12 Ton
Ø 80 mm
800 ㎟
60kW
CNC Friction Welding Machine with 22 Ton Forging Force for Automotive Engine Parts
CNC Friction Welding Machine with 22 Ton Forging Force for Automotive Engine Parts
CNC 22SF
2,000 rpm
22 Ton
Ø 45 mm
1,500 ㎟
60kW
CNC Friction Welding Machine 8DF for Shock Absorber

CNC Friction Welding Machines for Shock Absorbers

CNC Friction Welding Machines for Drive Shafts

CNC Friction Welding Machines for Drive Shafts

CNC Friction Welding Machine with 12 Ton Forging Force for Propeller Shafts

CNC Friction Welding Machine with 12 Ton Forging Force for Propeller Shafts

CNC Friction Welding Machine with 22 Ton Forging Force for Automotive Engine Parts

CNC Friction Welding Machine with 22 Ton Forging Force for Automotive Parts

Rotary Friction Welding Machine Options

Rotary Friction Welding Machine

Process Monitoring | PC monitoring | rotary friction welding

Process Monitoring

  • Displays important parameters
  • Data from every weld is stored and easily retrieved

Information Displayed

  • Machine status and diagnostics
  • Welding parameter database
  • Record of each welding cycle
  • Alarm conditions
Flash Removal | Rotary Friction Welding

Flash Removal

Turning

  • Applicable to rotary machines only (1-and 2-axis NC)

Shearing

  • I.D. or O.D. flash can be sheared off directly
  • Applicable to non-rotary machines only
Angle Control | Rotary Friction Welding

Angle Control

  • Mechanically or electronically controlled angles on both ends of the product after welding when certain angles are required for the application such as propeller shafts
Auto Stopper | Rotary Friction Welding

Auto Stopper

  • Reduce cycle time via precisely controlled speed using servo motors

Business Case: Friction Welding for Oil & Gas Ball Drop System Supplier for Fracturing Ball Manufacturing

A Texas-based global oil & gas ball drop system supplier for oil and gas wells finds Model 50SF as an answer to its need to weld aluminum blanks with a wide range of lengths up to a maximum of 5,000 ㎟ welding area. Their aluminum balls are welded and processed for use as fracturing balls in wells.

 

This client provides drilling pipe solutions for technically challenging applications in open wells in the oil and gas industry. When we worked with this drill rod manufacturer, they were familiar with the advantages of friction welding over other conventional welding methods, and the friction welding technology, and were already equipped with a few friction welding machines at their factories.

 

They were interested in Model 50SF, a hydraulic based single friction welding head machine. They sent us their aluminum blanks as samples which we welded with our hydraulic friction welding machine and sent back for quality tests. 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 U-Jin Tech’s manufacturing site in Korea and decided to purchase the Model 50SF because it has the capability to handle wider range of blank lengths than their current machines and reduces the loss of aluminum blanks with more precise control.

 

Our friction welding machines precisely control joining time and forging force required to minimize flash and material loss for manufacturers while achieving a high welding quality.

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 tube production plant when they needed to increase their production size with reduced cycle time and reduced material costs to meet their growing client base.

 

This client was looking to add a fully automated rotary friction welding line with an auto 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 8 ton forging force machine with double rotary friction welding heads and a flash shearing unit attached to the line. 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.

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