Rotary Friction Welding Machines

Rotary Friction Welding Solution for Electric Vehicle Battery Terminals, E-Mobility Components, Shafts, and Drill Pipes

LPR Global’s rotary friction welding machines are equipped with patented hydraulic chuck structure, steel bar structure, friction welding apparatus, and power steering main shaft mechanics. Rotary friction welding is preferred by e-mobility component manufacturers to join electric vehicle battery terminals and motor shafts.

 

In addition, rotary friction welding is widely used by automotive part manufacturers to produce camshafts, pistons, propeller shafts, engine valves, shock absorber rods, torque converters, and rear axle housings. Our friction welding machines are known to minimize material loss and burr for automotive sectors by exerting precise control over the joining time, welded length and forging force.

 

LPR Global’s CNC controlled friction welding machines and hydraulic servo type friction welding machines are used by clients in the oil and gas industry to produce drilling pipes and frac balls. Automated features allow clients to operate our friction welding machines with minimum training.

 

Our friction welding machines are manufactured in South Korea. Machine installation and aftersales support are provided by local engineers.

Please contact us for more information, or submit your RFQ package to [email protected] to receive a project quote.

Rotary Friction Welding Machine for E-Mobility Components

E-Mobility component and electric vehicle battery terminal manufacturers choose LPR Global’s friction welding machines over competitors for two reasons:

    1. Our machine is designed and built on multiple patents on welding technology of alloy metals and on mechanical structures for superior precision and control over the joining of dissimilar metals.
    2. Mechanical structure technology in the friction welding apparatus, hydraulic chucks, and power steering main shaft mechanics for stable and firm grip of workpieces during welding process and consistent shaft centricity throughout welding process.

 

Clients can choose from CNC rotary friction welding machines and hydraulic servo friction welding machines, depending on their application and requirements. The rotary friction welding machines come with automated loading and unloading conveyor system options. For clients who arrange NG parts before the friction welding process, we provide contact based, non-contact based, or both inspection systems in our feeding conveyor.

 

As a global leader in friction welding technology, 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.

 

The rotary friction welding machine model 8SF, which features 8-ton forging force for single sided friction welding, 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, while model CNC 12DF is a favorite among propeller and drive shaft manufacturers for high precision and short cycle time. See our full product line in our brochure or explore Hydraulic Friction Welding Machines and CNC Friction Welding Machines on this page. We offer customized options for clients’ specific needs.

 

Rotary Friction Welding Process for Automotive, Construction, Electric, and Machine Components

 

Friction Welding Process for Automotive Components
Torque converters, electric battery connectors, battery cables, camshafts, propeller shafts, intermediate shafts, drive shafts, universal joints, constant velocity joints, shock absorber rods, push rods, turbo chargers, engine valves, engine pistons, compressor pistons, rear axle shafts, brake pistons, yoke shafts, rear axle housings, torque rods, and motor shafts

 

pdf-iconFriction Welding Machine for Automotive Parts

pdf-iconFriction Welding Machine for Torque Converters

 

Friction Welding Process for Construction Machine Components
Hydraulic piston rods, hydraulic pump pistons, track roller bushings, and Track rollers

 

Friction Welding Process for Electric Components
Electric cable connectors, battery cables, bus bars

 

Friction Welding Process for Machinery Components and Structural Components
Print rollers, T-shaped bars for LNG gravity-based structures, ball screws, gear shafts, drill pipes, shower heads, aluminum blanks for fracturing system balls, steel balls, bolts, valve bodies and flanges

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

Friction Welded Pipes, Bars, and Plates

Friction welding solves design challenges by using 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.

Welding Interface and Design 

Bar + Bar

bar and bar | rotary friction welding

Bar + Bar

bar and bar | rotary friction welding combination

Optimal shape in the welding zone considering 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

Joining method that best conceals or removes flash

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 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 instances where manufacturing costs are reduced by replacing forged parts with sintered or powder metal pressed parts, friction welding technology is used to weld partly forged material and powder pressed material together.

Rotary Friction Welding Process | Advantages

Dissimilar metals can be joined

  • Steel + Stainless steel
  • Steel + Powder metal
  • Cu, Al + Stainless steel

Non ferrous metal can be joined

  • Al + Cu
  • Al + Al or Cu + Cu

Reduces material cost & forging cost

  • Substitution of non-critical part to a less costly material by friction welding.
  • Full forging to partial forging and friction welded components
Friction Welding Reduces Cost

Reduction in parts weight 

  • Substitution of forged bars with tubes
Friction Welding Reduces Component Weight

Improvement in manufacturing process 

  • Gundrilling can be replaced with friction welding pipes to bars.
Friction Welding over Gun Drilling

Leak inspection is no longer required 

  • Enhanced air tightness at the joining section
Friction Welding Torque Converter

Hydraulic Friction Welding Machines

Hydraulic Rotary Friction Welding Machine

Hydraulic Rotary Friction Welding Machines

Welding cycle graphics (Touch screen PC)

Welding cycle graphics (Touch screen PC)

Improve Productivity

  • Shortened welding cycle time and increased efficiency
  • Simple and easy operation with very little training required
  • Automated welding allows for redeployment of skilled labor
  • Minimal preparation required on welding materials
  • Low energy consumption
Machine Specs
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)
Hydraulic SF (Single Spindle)
DF (Double Spindle)
DF (Double Spindle)
Friction Welding Machine
Model
Spindle Speed
Max. Forging Force
Max. Solid Diameter
Max. Weld Area
Spindle Drive Motor
Friction Welding Machine for camshafts and engine valves
8-Ton Forging Force for Camshafts and Engine Valves
8 SF
1,700 rpm
8 Ton
Ø 28 mm
600 ㎟
17.5kW
Friction Welding Machine for Electrical Connectors
10-Ton Forging Force for Motor Shafts and Cable Connectors
10 SF
2,700 rpm
10 Ton
Ø 32 mm
800 ㎟
17.5kW
10-Ton Forging Force for Intermediary Shafts
10-Ton Forging Force for Intermediary Shafts
10 DF
2,000 rpm
10 Ton
Ø 32 mm
800 ㎟
30kW
15-Ton Forging Force for Propeller Shafts
15-Ton Forging Force for Propeller Shafts
15 DF
2,300 rpm
15 Ton
Ø 60 mm
1,100 ㎟
60kW
50-Ton Forging Force for Aluminum Blanks for Fracturing Balls
50-Ton Forging Force for Aluminum Blanks for Fracturing Balls
50 SF
1,500 rpm
50Ton
Ø 100mm
4,000 ㎟
90kW
60-Ton Forging Force for Propeller Shafts
60-Ton Forging Force for Propeller 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
60-Ton Forging Force for Drill Pipes
60 DF
1,500 rpm
60 Ton
Ø 145 mm
5,000 ㎟
83kW
100-Ton Forging Force for Track Rollers
100-Ton Forging Force 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 setup time with automatic length adjustments with a servo
  • Reduce cycle time with precise servo-controlled speed
  • Increase operational stability by reducing fluctuations in oil temperature

 

Machine Specs
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°
±0.5°
±0.5°
±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)

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

Rotary Friction Welding Machine Options

Rotary Friction Welding Process Monitoring

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 cylindrical shaped workpieces (1-and 2-axis NC)

Shearing

  • I.D. or O.D. flash can be sheared off directly
  • Applicable to non-cylindrical shaped workpieces
Angle Control | Rotary Friction Welding

Angle Control

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

Auto Stopper

  • Reduce cycle time via precisely controlled speed using servo motors

Rotary Friction Welding Machine Video

Business Case: Friction Welding for E-Mobility Battery Lug Manufacturing

Process Specifications

  • Cycle Time, including Loading and Unloading: 15 seconds
  • Welding Quality Control: Mismatch of axis within 0.15 sq mm for the surface area
  • Length Control: Mismatch of axis within 0.5 mm for the length

Rotary Friction Welding for Bimetallic Battery Lug Manufacturing 

 

Rotary friction welding machines are uniquely suited for manufacturing e-mobility battery components, such as bimetallic battery lugs. E-mobility batteries, or EV batteries, and wiring components have distinct requirements as they must operate at higher voltages and electric currents than conventional (ICE) vehicles while remaining cost-competitive and lightweight. 

 

Bimetallic battery lugs made of copper and aluminum are suitable for e-mobility battery applications, as they allow the electric system to leverage the high conductivity of copper and the low weight and low cost of aluminum. Welding is a crucial step in the production of bimetallic battery lugs, as the process creates a stable interface between aluminum and copper to prevent galvanic corrosion (galvanic action) caused by contact between two dissimilar metals. 

 

Rotary friction welding can weld two dissimilar metals unlike conventional fusion welding methods. With a high degree of welding quality control and precise application of upset (applied lateral force), our rotary friction welding machines can meet the exact dimensioning and precision welding requirements of battery lugs to quickly and repeatedly produce high-quality lugs and other battery components.

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.

Friction Welding AL Blanks for Fracturing Balls
Aluminum blanks friction welding for fracturing balls | rotary friction welding
Friction Welding Machine Aluminum Fracturing Balls

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.

CNC Friction Welding Machine Shock Absorber
Friction Welding Shock Absorber Rods

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
longitudinal section.

 

Material Specification
End plates dimensions: Width 30mm-110mm / Length 60mm to 110mm / Thickness 14mm to 25mm
Reinforcement bars: Diameter 15mm- 32mm.

Friction Welding Machine for T-bars in LNG Gravity Based Structures
Welded T-bars for LNG Gravity Structures

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:

  • Driveshafts
  • Propeller Shafts
  • Intermediate Shafts
  • Constant Velocity Joints
Friction Welding Torque Converter
Friction Welding Machine_for Torque Converter

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