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10 INTERNATIONAL SCIENTIFIC CONFERENCE

19 – 20 November 2010, GABROVO

FRICTION WELDING OF DIFFERENT MATERIALS

Mümin ŞAHİN
Trakya University Faculty of Eng. and Arch. Dept. Mech. Eng. 22180, Edirne-Turkey

Abstract
In general, any machine part can be produced by one of various manufacturing methods such as forging,
machining, casting and welding. Determination of the manufacturing method depends on production costs of the
alternatives for individual parts. Friction-welding which also is an alternative welding method, is widely used in
production of machine parts having different cross-section or diameter in order to decrease manufacturing costs. For
this reason, friction welding is getting higher share among the other welding methods. In the process, heat is generated
by conversion of mechanical energy into thermal energy at the interface of the work pieces during rotation under
pressure without use any energy from outside. Generally, friction-welding method is divided by as continuous drive and
inertia friction welding. In the presented study, it was given the knowledge about friction welded different materials by
the author.

Keywords: Friction Welding, Steel, Aluminium, Copper

INTRODUCTION welding process where metallic bonding is

Friction welding can be achieved at high produced at temperatures lower than the
production rates and therefore is economical in melting point of the base metals. Friction time,
operation. In applications where friction friction pressure, forging time, forging
welding has replaced other joining processes, pressure and rotation speed are the most
the production rate has been increased interesting parameters in the friction welding
substantially. method [1].
When joining dissimilar metals such as In practice, friction welding is classified in
copper and steel, friction welding is of great two ways as continuous drive friction welding
importance in applications. Welding is and inertia friction welding [2-4]. In the
possible within the limited range of the continuous drive friction method shown in
welding conditions although problems for Figure 1, one of the components is held
welding exist because of brittle intermetallic stationary while the other is rotated at a
compounds and high thermal conductivity. To constant speed (s). The two components are
minimize the problems, the friction welding brought together under axial pressure (Pf) for a
parameters must be taken into consideration certain friction time (tf). Then, the clutch is
for strong welds. separated from the drive, and the rotary
component is brought to stop within the
As it is known, friction welding is used braking time while the axial pressure on the
extensively in various industries nowadays. stationary part is increased to a higher upset
Heat in friction welding is generated by pressure (Pu) for a predetermined upset time
conversion of mechanical energy into thermal (tu). Parameters of the method are shown in
energy at the interface of the work pieces Figure 2.
during rotation under pressure. Various ferrous
and non-ferrous alloys, which have circular or FRICTION WELDED DIFFERENT
non-circular cross sections, having different MATERIALS
thermal and mechanical properties can easily Surface cleanliness in terms of
be joined by the friction welding method. contaminants, especially grease, reduces the
Friction welding is classified as a solid-state quality of joints. The cleanliness of the parts

Международна научна конференция “УНИТЕХ’10” – Габрово II-131

must be considered as important as well. The maximum strength obtained in the
Therefore, the ends of the parts were cleaned joints has about 94% that of aluminium parts
prior to the welding process to minimize the having the weakest strength. Micro-hardness
effect of organic contamination in the welding test results on the horizontal distance of joints
zone by acetone [5-14]. are shown in Fig.4. As can be seen in Fig.4,
the increase noted is the steel side.
- Friction Welded Stainless Steel and
Aluminium Materials - Friction Welded Stainless Steel and
Light non-ferrous metals such as aluminium Copper Materials
and magnesium alloys have drawn much When joining dissimilar metals such as
attention as regards application since they are copper and steel, friction welding is of great
energy-saving. Above all, aluminium alloys importance in applications. Welding is
are used more due to their superior workability possible within the limited range of the
and less expensive cost. However, they are not welding conditions although problems for
entirely changed with stainless steel having welding exist because of brittle intermetallic
superior strength and good weldability in compounds and high thermal conductivity. To
various structures. Therefore, it is necessary to minimize the problems, the friction welding
join stainless steel and aluminium materials [5- parameters must be taken into consideration
9, 11, 12]. Then, macrophoto and hardness for strong welds [5-9, 11, 13]. Then,
distribution on the horizontal distance of joints macrophoto and hardness distribution on the
are given in Figures 3 and 4, respectively. horizontal distance of joints are given in
Figures 5 and 6, respectively.
1. Motor
2. Brake
3. Rotating Chuck
4. Non Rotating Chuck
5. Rotating Workpiece
6. Non Rotating Workpiece
5 6 7. Hydraulic Cylinder
1 2
3 4 7

Fig. 1. Layout of Continuous Drive Friction Welding

Braking
Friction Time (tf)
Parameters

Upsetting (tu)

Rotation Speed (s) Upsetting

Pressure (Pu)

Friction Pressure (Pf)

Torque (T)
Shortening

Welding Welding
Started Time Completed

Fig. 2. Parameters for Continuous Drive Friction Welding

II-132 Международна научна конференция “УНИТЕХ’10” – Габрово

 Stainless Steel (AISI 304) - Copper
( d=10mm-d=10mm )
300
Stainless Steel 275 Copper
250
225

Vickers Hardness (HV)

200
175
150
Aluminium Stainless Steel
x3 125
100
Fig. 3. Photo of joint 75
50

Stainless Steel (AISI 304) -Aluminium

25
( d1=10mm-d2=10mm ) 0
-4 -3 -2 -1 0 1 2 3 4
Horizontal Distance (mm)
300
275
250
225 Fig. 6. Hardness Distribution on the Horizontal
Vickers Hardness (HV)

200 Distance of Joints

175
150
125 Micro-hardness test results on the
100
75
horizontal distance of joints are shown in
50 Fig.6. It can be seen that around the interface,
the hardness of the copper increases slightly.
25
0
-4 -3 -2 -1 0 1 2 3 4

Horizontal Distance (mm)

- Friction Welded Aluminium and Copper
Materials
Fig. 4. Hardness Distribution on the Horizontal
Aluminium and copper are continually
Distance of Joints replacing steels in electricity supply systems to
reduce cost. However, welding of copper and
aluminium are usually difficult by
conventional fusion welding processes because
those have the high thermal diffusivity higher
than in many steels alloys. To overcome the
problem the friction welding which is one of
the solid state welding techniques is applied to
the joining of copper and aluminium material
[5-9, 11, 14]. Then, macrophoto and hardness
distribution on the horizontal distance of joints
are given in Figures 7 and 8, respectively.

Al.

Stainless-Steel Copper
x3
X3
Fig. 5. Photo of Joint

Copper
It was found that the maximum strength
obtained in the joints is about 75% that of
copper parts having the weakest strength. Fig. 7. Macro-photo of joint

Международна научна конференция “УНИТЕХ’10” – Габрово II-133

 Coppe r - Alum inium [4] Murti, K. G. K., Sundaresan, S., Parameter
( d=1 0 m m -d=1 0 m m ) Optimisation in Friction Welding Dissimilar
15 0
Materials, Metal Construction, June, 1983, pp.
Copper Aluminium 331-335.
Side 12 5 Side [5] Yılbas, B. S., Şahin, A. Z., Kahraman, N., Al –
V ic k er s Har dnes s (H

10 0
Garni, Friction Welding of St - Al and Al- Cu
Materials, Journal of Materials Processing
75 Tecnology, (1995), v 49 n 3-4 Feb15., pp. 431-
50
443.
[6] Yılbas, B. S., Şahin, A. Z., Çoban, A., Abdul
25
Aleem, B. J., Investigation into the Properties
0
of Friction –Welded Aluminium Bars, Journal
-4 -3 -2 -1 0 1 2 3 4 of Materials Processing Tecnology, (1995), v
Horizonta l Distanc e (m m )
54, pp. 76-81.
[7] Rhodes, C. G., Mahoney, M. W., Bingel, W.
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the Joints Friction Stir Welding on Microstructure of
7075 Aluminium, Scripta Materialia, (1997), v
As it is shown in Figure 8, the hardness 36 n 1, pp. 69-75.
variations on the copper side are more than [8] Fukumoto S, Tsubakino H, Okita K, Aritoshi
those on the aluminium side. This variation is M, Tomita T., Amorphization by Friction
possible due to comparatively high thermal Welding between 5052 Aluminum Alloy and
conductivity of copper material. 304 Stainless Steel. Scripta Materialia, (2000),
V 42, pp 807-812.
[9] Fukumoto S, Tsubakino H, Okita K, Aritoshi
CONCLUSIONS M, Tomita T., Friction Welding Process of
• Because of the existence of intermetallic 5052 Aluminium Alloy to 304 Stainless Steel.
phase, the welding of non-ferrous metals is very Materials Science and Technology, September,
hard. But, continuous drive friction welding (1999), Vol. 15, pp 1080-1086.
method can suitably be adopted for welding of [10] Şahin, A. Z., Yılbaş, B. S., Ahmed, M.,
different ferrous and non-ferrous materials. Nickel, J., Analysis of The Friction Welding
• Tensile strengths for joints were considered Process in Relation to The Welding of Copper
as positive result when compared with those of and Steel Bars, Journal of Materials
the base metals. But, some of the welds show Processing Technology, v 82, (1998), 127-
136.
poor strength depending on some accumulation [11] ASM, Welding And Brazing, Metals
of alloying elements at the interface result of Handbook, ASM, Metals Park. Ohio: 507-
temperature rise and the existence of a grey 518, 8th Edition.
layer. [12] Sahin, M., Joining of stainless-steel and
• The hardness variations are harmonious aluminium materials by friction welding, The
with previous works. International Journal of Advanced
Manufacturing Technology, Volume 41, Issue
5, 2009, pp: 487-497.
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