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1st Edition

Prepared by the
American Welding Society (AWS) C6 Committee on Friction Welding
Under the Direction of the
AWS Technical Activities Committee
Approved by the
AWS Board of Directors

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This specification provides for the qualification of friction welding machines, procedures, and training of welding operators.
Qualification of the welding procedure specification (WPS) includes the material specifications involved, weld joint design,
destructive and nondestructive examination requirements, as well as guidelines for different categories of quality assurance.
Qualification of welding equipment includes weld parameter control and weld reproducibility.
Welding operators require training in the proper operation of friction welding equipment. The requirements for requalification of the WPS and equipment are also given.

550 N.W. LeJeune Road, Miami, FL 33126

International Standard Book Number: 0-87171-631-3

American Welding Society
550 N.W. LeJeune Road, Miami, FL 33126
2006 by American Welding Society
All rights reserved
Printed in the United States of America
Photocopy Rights. No portion of this standard may be reproduced, stored in a retrieval system, or transmitted in any
form, including mechanical, photocopying, recording, or otherwise, without the prior written permission of the copyright
owner.
Authorization to photocopy items for internal, personal, or educational classroom use only or the internal, personal, or
educational classroom use only of specific clients is granted by the American Welding Society provided that the appropriate
fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, tel: (978) 750-8400; Internet:
<www.copyright.com>.

ii

- All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American
Welding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of the
American National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, or
made part of, documents that are included in federal or state laws and regulations, or the regulations of other governmental bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWS
standards must be approved by the governmental body having statutory jurisdiction before they can become a part of
those laws and regulations. In all cases, these standards carry the full legal authority of the contract or other document
that invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirements
of an AWS standard must be by agreement between the contracting parties.
AWS American National Standards are developed through a consensus standards development process that brings
together volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the process
and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or
verify the accuracy of any information or the soundness of any judgments contained in its standards.
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether
special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance
on this standard. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information
published herein.
In issuing and making this standard available, AWS is not undertaking to render professional or other services for or on
behalf of any person or entity. Nor is AWS undertaking to perform any duty owed by any person or entity to someone
else. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the
advice of a competent professional in determining the exercise of reasonable care in any given circumstances.
This standard may be superseded by the issuance of new editions. Users should ensure that they have the latest edition.
Publication of this standard does not authorize infringement of any patent or trade name. Users of this standard accept
any and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the infringement of
any patent or product trade name resulting from the use of this standard.
Finally, AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.
On occasion, text, tables, or figures are printed incorrectly, constituting errata. Such errata, when discovered, are posted
on the AWS web page (www.aws.org).
Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request,
in writing, to the Managing Director, Technical Services Division, American Welding Society, 550 N.W. LeJeune Road,
Miami, FL 33126 (see Annex D). With regard to technical inquiries made concerning AWS standards, oral opinions
on AWS standards may be rendered. However, such opinions represent only the personal opinions of the particular
individuals giving them. These individuals do not speak on behalf of AWS, nor do these oral opinions constitute official
or unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as a
substitute for an official interpretation.
This standard is subject to revision at any time by the AWS C6 Committee on Friction Welding. It must be reviewed
every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations, additions,
or deletions) and any pertinent data that may be of use in improving this standard are required and should be addressed
to AWS Headquarters. Such comments will receive careful consideration by the AWS C6 Committee on Friction Welding
and the author of the comments will be informed of the Committees response to the comments. Guests are invited to
attend all meetings of the AWS C6 Committee on Friction Welding to express their comments verbally. Procedures for
appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the Technical
Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 550 N.W. LeJeune
Road, Miami, FL 33126.

iii

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iv

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AWS C6 Committee on Friction Welding
T. J. Lienert, Chair
T. Stotler, Vice Chair
S. Morales, Secretary
D. C. Adams
C.W. Carrier
J. J. Donohue
J. W. Fischer
*J. R. Huber
G. A. Knorovsky
D. L. Kuruzar
J. Price
H. W. Seeds
A. S. Wadleigh
D. J. Walsh
R. R. Xu

Los Alamos National Laboratory

EWI
American Welding Society
Manufacturing Technology, Incorporated
General Electric Company
American Friction Welding, Incorporated
American Friction Welding, Incorporated
A R D Industries Limited
Sandia National Laboratories
Manufacturing Technology, Incorporated
Thompson Friction Welding
American Axle and Manufacturing
Interface Welding
Walsh Friction Welding, Incorporated
Rolls-Royce Corporation

*Advisor

This page is intentionally blank.

vi

This foreword is not a part of AWS C6.2/C6.2M:2006, Specification for Friction

Welding of Metals, but is included for informational purposes only.

This Specification for Friction Welding is the second publication of the AWS C6 Committee on Friction Welding. The
committee was formed to recognize, codify, develop, and advance the process of friction welding.
The committees first publication, ANSI/AWS C6.1-89, Recommended Practices for Friction Welding, was completed
and published in 1989. It was the culmination of a monumental task: assembling and reducing into a concise form the
technology and history of friction welding.
It was recognized at that time that a second document, a specification, would be required. A task force from within the
AWS C6 Committee was formed to prepare a specification for approval.
The purpose of this specification is to help ensure that the welds resulting from the use of the process meet the service
requirements for which they are intended.
This document clearly and accurately describes the essential technical requirements for a friction weld. It specifies the
qualification of procedures, methods, and equipment necessary to meet its technical requirements and safe use. This
specification is intended to be used when referenced by other specifications or contract documents.
Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary,
AWS C6 Committee on Friction Welding, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.
Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request,
in writing, to the Managing Director, Technical Services Division, American Welding Society. A formal reply will be
issued after it has been reviewed by the appropriate personnel following established procedures.

vii

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viii

Personnel......................................................................................................................................................................v
Foreword ....................................................................................................................................................................vii
List of Tables ................................................................................................................................................................x
List of Forms.................................................................................................................................................................x
1.

Scope.....................................................................................................................................................................1

2.

Normative References .........................................................................................................................................1

3.

Terms and Definitions.........................................................................................................................................1

4.

Process Description .............................................................................................................................................3

5.

General Requirements ........................................................................................................................................3

5.1 Overview......................................................................................................................................................3
5.2 Equipment Requirements.............................................................................................................................4
5.3 Material Requirements.................................................................................................................................4
5.4 Weld Joint Design........................................................................................................................................4

6.

Welding Procedure Specification (WPS) Qualification...................................................................................4

6.1 WPS Qualification Requirement .................................................................................................................4
6.2 Allowable Parts for WPS Qualification Purposes .......................................................................................4
6.3 Examination of Parts Welded to Qualify a WPS.........................................................................................4
6.4 Circumstances Mandating Requalification..................................................................................................4
6.5 Machine-Specific Nature of a WPS.............................................................................................................5
6.6 Requalification Procedure Requirements ....................................................................................................5

7.

Welding Operator Qualification ........................................................................................................................5

7.1 Overview......................................................................................................................................................5
7.2 Safety ...........................................................................................................................................................5
7.3 Operator Qualification Requirements..........................................................................................................5
7.4 Operator Requalification Requirements ......................................................................................................5

8.

Quality Assurance ...............................................................................................................................................5

8.1 Overview......................................................................................................................................................5
8.2 Categories ....................................................................................................................................................5
8.3 WPS Qualification-Acceptance Criteria......................................................................................................6
8.4 Production Quality Assurance .....................................................................................................................6

Annex A (Informative)Safe Practices ......................................................................................................................7

Annex B (Informative)Bibliography ......................................................................................................................11
Annex C (Informative)Sample Forms ....................................................................................................................13
Annex D (Informative)Guidelines for the Preparation of Technical Inquiries ......................................................19
List of AWS Documents on Friction Welding ...........................................................................................................21

ix

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1

Production Quality-Assurance Categories...................................................................................................5

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C1
C2
C3
C4

Weld Procedure Specification (WPS) Example for Direct-Drive Friction Welding.................................14
Weld Procedure Specification (WPS) Example for Inertia Friction Welding...........................................15
Weld Procedure Specification (WPS) Example for Friction Stir Welding ...............................................16
Weld Procedure Specification (WPS) Example for Production Sampling................................................17

1. Scope

AWS Documents:2
1. AWS A2.4, Standard Symbols for Welding, Brazing,
and Nondestructive Examination;

This document specifies the requirements for the manufacture and quality assurance of friction weldments. It
also contains requirements for the qualification of welding machines, welding procedures, and welding operators. This specification is directly applicable to inertia,
direct-drive, and friction stir variants of friction welding,
but may also be used with orbital, angular reciprocating,
and linear reciprocating variants.

2. AWS A3.0, Standard Welding Terms and Definitions;

3. AWS B1.10, Guide for the Nondestructive Examination of Welds;
4. AWS B2.1, Specification for Welding Procedure
and Performance Qualification;

This standard makes use of both the U.S. Customary

Units and the International System of Units (SI). The
latter is shown within brackets or in appropriate columns
in tables and figures. The measurements may not be
exact equivalents; therefore, each system shall be used
independently.

5. AWS B4.0 and/or B4.0M, Standard Methods for

Mechanical Testing of Welds;

Safety and health issues and concerns are beyond the

scope of this standard, and therefore not fully addressed
herein. Safety and health information is available from
other sources, including, but not limited to, ANSI Z49.1,
Safety in Welding, Cutting, and Allied Processes1 and
applicable federal and state regulations.

7. ANSI Z49.1, Safety in Welding, Cutting, and

Allied Processes.

6. AWS C6.1, Recommended Practices for Friction

Welding;
Other Documents:

3. Terms and Definitions

The following includes friction welding terms not listed
in AWS A3.0, Standard Terms and Definitions. Standard
terms found in AWS A3.0 are listed in italics. Lightface
indicates nonstandard terms. For the purpose of this document, the following terms and definitions apply:

2. Normative References

angular reciprocating friction welding. A variation of

the friction welding process in which the relative
motion between the faying surfaces describes an arc
of less than 180 and reverses direction repeatedly
during the friction phase.

The following normative (mandatory) references contain

provisions which, through reference in this text, constitute provisions of this AWS standard. For dated references, subsequent amendments to, or revisions of, any of
these publications do not apply. However, parties to
agreements based on this AWS standard are encouraged
to investigate the possibility of applying the most recent
editions of the documents shown below. For undated
references, the latest edition of the standard referred to
applies.

braking delay. The period of time between the cessation

of the drive producing relative motion of the workpieces, and the start of external braking.
braking phase. That portion of the welding cycle during
which the external brake is applied.

1 ANSI

2 AWS standards are published by the American Welding Society,

Z49.1 is published by the American Welding Society,

550 N.W. LeJeune Road, Miami, FL 33126.

550 N.W. LeJeune Road, Miami, FL 33126.

braking rate. The reduction in speed vs. time during the

braking phase.

forge delay time. The time between the cessation of

drive and the initiation of the forge force.

braking time. The duration of the braking phase.

forge force. A compressive force applied to the faying

surfaces after the friction phase of the welding cycle
is essentially complete.

continuous-drive friction welding. See direct-drive

friction welding.

forge length. The change in component length which

occurs during the forge phase.

cooling dwell. The time from the cessation of relative

motion until the forge force is released, during which
time the weld cools.

forge phase. The portion of the friction welding cycle

during which the forge force is applied to the faying
surfaces.

direct-drive friction welding. A variation of friction

welding in which the energy required to make the
weld is supplied to the welding machine through a
direct motor connection for a preset period of the
welding cycle.

forge time. The duration of the forge phase.

friction force. Nonstandard term. See friction welding
force.

dwell after plunge. The time between when the friction

stir welding (FSW) tool has reached its final position
and the initiation of the next processing step (typically the travel sequence).

friction phase. The portion of the friction welding cycle

during which the heat necessary for welding is generated by relative motion and the application of a friction force at the faying surface. Friction phase is
comprised of both first friction (if used) and second
friction.

dwell at end of travel. The time between the end of the

travel sequence and the beginning of the next processing step (typically FSW tool removal).

friction speed. The relative velocity of the workpieces at

the time of initial contact.

engineer. The person responsible for all aspects of

friction welding at the contractors site.
external braking. Forced reduction in the speed of relative motion by a built-in braking unit, either internal
to the motor or a separate mechanical brake.

friction stir welding (FSW). A variation of friction welding that produces a weld between two butting workpieces by the friction heating and plastic material
displacement caused by a high-speed rotating tool that
traverses along the weld joint.

faying surface. The mating surface of a member that is

in contact with, or in close proximity to, another
member to which it is to be joined.

friction surfacing. Surfacing or cladding in which

the principle of friction welding is used to deposit
material.

first friction force. The compressive force applied to the

faying surfaces during the first friction phase.

friction time. The duration of the friction phase.

friction upset distance. The decrease in length of the
workpieces during the time of friction welding force
application.

first friction phase. An optional application of a

reduced friction welding force at the beginning of the
welding cycle.

friction welding (FRW). A solid-state welding process

that produces coalescence of materials under compressive force contact of workpieces rotating or
moving relative to one another to produce heat
and plastically displaced material from the faying
surfaces.

first friction time. The duration of the first friction

phase.
flash curl. See weld flash.
flash roll. See weld flash.

friction welding force. The compressive force applied to

the faying surfaces during the friction phase.

flywheel energy. The total kinetic energy stored in the

rotating mass of an inertia friction welding machine
when the friction welding force is applied.

FSW tool. The fabricated tool that processes the materials to be stirred or joined.

flywheel friction welding. A variation of friction welding

in which the energy required to make the weld
is supplied by the rotational kinetic energy of the
welding machine. Also, nonstandard term for inertia
friction welding.

heat-affected zone (HAZ). The portion of the base metal

whose mechanical properties or microstructure have
been altered by the heat of welding, brazing, soldering, or thermal cutting.
2

hybrid friction welding. A variation of friction welding

in which the energy required for welding is supplied
by more than one source.

percent increase in interface area, a reduction in

length, a percent reduction in lap joint thickness, or a
reduction in cross wire weld stack height.

inertia friction welding. A variation of friction welding

in which the energy required to make the weld is supplied by the stored rotational kinetic energy of the
welding machine.

upset distance. The total loss of axial length of the workpieces from the initial contact to the completion of the
weld.
upset force. The force exerted at the faying surfaces during upsetting.

linear reciprocating friction welding. A variation of

the friction welding process in which the relative
motion between the faying surfaces is linear and
reverses direction repeatedly during the friction
phase.

upset speed. The RPM at which the axial force is

increased (typically used with inertia-friction welding), if necessary, to the forge force. See also forge
phase.

orbital friction welding. A variation of the friction

welding process which produces an elliptical motion
between the faying surfaces.

upset time. The time during upsetting.

weld flash. The material which is displaced from the
friction weld interface.

plunge. The act of pushing the FSW tool into the material to be stirred.

weld interface. The interface between weld metal and

base metal in a fusion weld, between base metals in a
solid-state weld without filler metal, or between filler
metal and base metal in a solid-state weld with filler
metal and in a braze.

prebond. The distance between the faying surfaces

immediately prior to the application of the friction
welding force.
radial friction welding. A variation of the friction welding process which can be used to join circular sections
where it is undesirable to rotate the parts to be joined,
or to join collars and bands to the inside or outside of
cylindrical sections. In this variation the applied
friction welding and forge forces between the faying
surfaces are normal to the axis of rotation.

weld speed. The RPM at which the weld force is applied

in inertia friction welding.

4. Process Description
Friction welding (FRW) is a solid-state joining process
that produces coalescence of materials under compressive force contact of workpieces rotating or moving relative to one another to produce heat and plastically
displace material from the faying surfaces. Filler metal,
flux, and shielding gas are not normally required with
this process. Use of the process is described in AWS
C6.1, Recommended Practices for Friction Welding as
well as in Chapter 23 of the Welding Handbook.3

second friction force. The compressive force applied to

the faying surfaces during the second friction phase.
second friction phase. The portion of the friction welding
cycle which, in conjunction with the first friction phase,
comprises the friction phase. This term has meaning
only when the optional first friction phase is used.
second friction time. The duration of the second friction
phase.
spin welding. Nonstandard term. See friction welding.

Friction stir welding (FSW) is a variation of FRW that

produces a weld between two butting workpieces by the
friction heating and plastic material displacement caused
by a nonconsumable high-speed rotating tool that
traverses along the weld joint.

surface velocity. The angular velocity measured at the

outer periphery of the faying surfaces.
travel speed. The rate at which the FSW tool translates
through the material.
unit energy. The stored flywheel energy of an inertia
friction welder divided by the area of the faying
surfaces.

5. General Requirements
5.1 Overview. Users of friction welding and friction stir
machines are expected to inform themselves of and

unit force. The compressive force applied to the faying

surfaces divided by the area of the faying surfaces.

3 OBrien,

upset. Bulk deformation resulting from the application of

pressure in welding. The upset may be measured as a

R. L., ed., 1991, Friction Welding, Vol. 2 of Welding

Handbook, 8th ed., Miami: American Welding Society.

6. Welding Procedure Specification

(WPS) Qualification

comply with applicable national and local requirements

regulating industrial practices.
5.2 Equipment Requirements

6.1 WPS Qualification Requirement. A WPS should

be qualified prior to production welding. Examples of
WPS forms appear in Annex C. An example of a Quality
Control form is also shown in Annex C (see Form C4).
The WPS must include a Quality Control form.

5.2.1 A machine capable of controlling the friction

speed, applied forces, and/or displacement rates/distances
such that it can produce welds made to a qualified welding procedure specification (WPS) within the tolerances
established is considered qualified.

6.2 Allowable Parts for WPS Qualification Purposes.

Parts used for WPS qualification purposes must be representative of those used for actual production parts in the
following respects:

5.2.2 The machine shall be equipped with an automatic control system which sequentially completes the
welding cycle without welding operator intervention
after initiation.

1. Chemical composition;

5.2.3 Systems that control machine-operating variables shall be calibrated according to the machine manufacturers recommendations. The maximum interval
between calibrations shall be twelve (12) months. The
calibration accuracy and precision shall be to a level
required to produce parts within tolerances established
by the WPS.

2. Faying surface condition;

3. Heat treatment condition;
4. Joint geometry and rotational mass;
5. Part dimensions; and
6. For FSW, a dimensioned drawing of the FSW tool.

5.2.4 The machine shall be set-up and verified to be in

conformance with the WPS by the appropriately trained
personnel as determined by the Engineer.

It is recommended that actual production parts be used

whenever feasible.
6.3 Examination of Parts Welded to Qualify a WPS.
For welds requiring postweld heat treatment (PWHT),
the examination shall take place after PWHT.

5.3 Material Requirements. Material properties necessary to fulfill the engineering drawing requirements
should be specified. Typical properties that may be
specified are the following:

6.3.1 Parts being evaluated to qualify a proposed

WPS shall undergo examination and testing as specified
on the appropriate engineering drawing. Acceptance criteria shall be included with the testing requirements.

1. The M-Number as shown in AWS B2.1, Specification for Welding Procedure and Performance Qualification;
2. The material heat treatment condition;

6.3.2 If not specified on the drawing, minimum examination, testing, and acceptance requirements are:

3. Metallurgical cleanliness; and/or

6.3.2.1 A minimum of two (2) parts shall be

welded for WPS qualification.

4. Maximum allowable discontinuities.

Other material requirements may be controlled by supplementary specifications.

6.3.2.2 A minimum of two (2) parts shall be examined. The examination shall include both a destructive
mechanical test and a metallographic examination. The
metallographic specimen shall be examined both macroscopically (1030X) and microscopically (100X).

5.4 Weld Joint Design. The joint should be specified by

a welding symbol (see AWS A2.4, Standard Symbols for
Welding, Brazing, and Nondestructive Examination) on
an assembly drawing. Features, which should be specified on process drawings prior to welding, include:

6.3.2.3 Acceptance or rejection shall be according

to standards established in Clause 8, Quality Assurance.

1. Dimensions (including tolerances);

6.4 Circumstances Mandating Requalification. A

WPS shall remain qualified unless the following occurs:

2. Faying surface finish;

1. Modifications or repairs that affect the welding

performance of the machine are made.

3. Faying surface cleanliness;

4. Heat treatment condition; and

2. Component dimensions exceed tolerances established in the WPS.

5. For FSW, a dimensioned drawing of the FSW tool.

4

3. Materials, material conditions, or both, change

from those specified in the WPS.

After such instruction, the welding operator shall demonstrate the ability to safely operate the machine and to
produce acceptable welds. Acceptance criteria for the
qualification test weld shall be determined by the Engineer. Welding operators shall be qualified for each WPS
used in production. Operator qualification shall be documented, using a Welding Performance Qualification
Record similar to that found in AWS B2.1, Specification
for Welding Procedure and Performance Qualification.

4. Faying surface conditions change from that specified on the WPS.

5. Unexplained nonconformity with WPS-mandated
quality-assurance requirements occurs.
6.5 Machine-Specific Nature of a WPS. A WPS is
developed for one specific welding machine; it shall not
be used on another machine without requalification,
except by agreement between the supplier and customer.

7.4 Operator Requalification Requirements. Requirements for requalification of operators are at the discretion of the Engineer.

6.6 Requalification Procedure Requirements. Requalification procedure requirements are identical to the
qualification procedure requirements.

8. Quality Assurance

7. Welding Operator Qualification

8.1 Overview. In order to manufacture quality friction

weldments, certain conditions must be met. The following paragraphs define these requirements.
Friction welds and friction stir welds are utilized in different applications in many different situations. Each
applications demands and each weldments fitness
for service requires particular and individual qualityassurance programs.

7.1 Overview. FRW/FSW is an automatic, machinecontrolled welding operation, thus operators do not
require welder certification. Instead, such personnel must
meet the requirements of this section.
7.2 Safety. Operators/setup personnel shall be trained in
safe operating practices and hazard-communication practices in accordance with the machine manufacturers
recommended safety procedures and national and local
safety regulations.

This section specifies three quality-assurance categories

that may be applied regardless of industry or product line
(see Table 1). The designer, product, manufacturing, or
process Engineer shall specify a quality-assurance category that is best suited to the welded component or
assembly. Exceptions to the requirements of this section
must be specified in contract documents or on the engineering drawings.

7.3 Operator Qualification Requirements. Appropriate instruction shall be given in the operation of a specific welding machine by the Engineer, or the welding
supervisor, or a previously qualified operator. Such
instruction shall include all items covered by a WPS for
which the operator is responsible. In those cases where
the operator does not have responsibility for machine
setup, the operator need not be instructed in machine
setup.

8.2 Categories (see Table 1)

8.2.1 Category A1. Every weld is checked visually
and by a nondestructive examination (NDE) method
listed in the latest edition of AWS B1.10, Guide for
Nondestructive Examination of Welds. Specified process

-- QualityAssurance
Category

Visual
Inspection

Dimensional
Inspection

Dimensional
Records

Process
Monitoring

Process
Records

NDE

Destructive
Testing

A1
A2
B1
B2
C

100%
100%
Sample
Sample
Sample

100%
100%
Sample
Sample
Sample

100%
100%
Sample
Sample
None

100%
100%
100%
100%
Sample

100%
100%
Optional
Optional
None

100%
100%
Sample
None
None

None
Sample
None
Sample
Sample

porosity. Acceptability of brittle phases must be evaluated on the basis of their effect on appropriate mechanical properties. Acceptance standards of the base metal
specifications shall be used to determine the acceptability of features resulting from inclusions and stringers in
the base metal.

monitoring parameters and physical dimensions for each

weldment shall be recorded. These records shall be
maintained for an agreed upon period of time.
8.2.2 Category A2. Every weld is checked visually
and by an NDE method listed in the latest edition of
AWS B1.10, Guide for Nondestructive Examination of
Welds. In addition, a bend test or other destructive test as
specified by the Engineer shall be performed in accordance with the latest edition of AWS B4.0 or B4.0M,
Standard Methods for Mechanical Testing of Welds.
Specified process monitoring parameters and physical
dimensions for each weldment shall be recorded. These
records shall be maintained for an agreed upon period of
time.

8.3.2 Mechanical Test Criteria. The mechanical test

of the weld specimen shall pass the criteria specified on
the engineering drawing. If no mechanical testing procedure is specified on the drawing, a bend test shall be performed in accordance with AWS B4.0:1998, Standard
Methods for Mechanical Testing of Welds. Test specimens defined in Parts A and D in AWS B4.0 may be
used depending upon the size of weldment being tested.
If specimens defined by Part A are used, they shall
include the center and edge of the weld where appropriate (i.e., solid bar welds) or at the beginning, middle, and
end of a FSW. Criteria for passing the bend test shall be
agreed upon between the weldment supplier and customer.

8.2.3 Category B1. An agreed upon weld sample

shall be checked visually and by an NDE method listed
in the latest edition of AWS B1.10, Guide for Nondestructive Examination of Welds. Specified process monitoring parameters for all weldments shall be within
acceptable limits, but not necessarily recorded. Physical
dimensions for an agreed upon sample of the weldments
shall be recorded and maintained for an agreed upon
period of time.

8.3.3 Documentation of Qualification Testing. Use

of a Procedure Qualification Record, such as is found in
AWS B2.1, Specification for Welding Procedure and
Performance Qualification, is suggested.

8.2.4 Category B2. An agreed upon weld sample

shall be checked visually. A bend test or other destructive test as specified by the Engineer shall be performed
on a specified sample number of weldments. Bend testing, if used, shall be in accordance with AWS B4.0 or
B4.0M. Specified process monitoring parameters for all
weldments shall be within acceptable limits, but not necessarily recorded. Physical dimensions for an agreed
upon sample of the weldments shall be recorded and
maintained for an agreed upon period of time.

8.4 Production Quality Assurance. To maintain acceptable production quality assurance the following shall
apply:
8.4.1 Welds shall be made by a qualified machine
operator according to the requirements of the WPS.
8.4.2 When machines are equipped with monitors,
they shall be set and used in accordance with the WPS.
8.4.3 Sampling of production welds shall be used for
quality assurance in accordance with the WPS. In the
absence of other contractual quality-assurance requirements, one (1) bend test shall be made and evaluated
according to the criteria given in 8.3.2 at the beginning of
each shift or after the machine has been idle for 8 or
more hours.

8.2.5 Category C. Sample weldments shall be visually and destructively examined, and shall have specified
process monitoring parameters and dimensions checked.
There are no record-keeping requirements. As a minimum, the beginning or end of a shift or batch is the most
appropriate time to perform these actions.

8.4.4 Statistical process control may be applied to

measure physical dimensions of the weldment, upset
length, or other process variables.

8.3 WPS Qualification-Acceptance Criteria. WPS

qualification-acceptance criteria are the following:
8.3.1 Metallographic Evaluation Criteria. The weld
zone, which includes the heat-affected zone (HAZ), shall
be free of discontinuities such as cracks, inclusions, and

8.4.5 Documentation shall be maintained for an

agreed upon period of time.

This annex is not a part of AWS C6.2/C6.2M:2006, Specification for Friction
Welding of Metals, but is included for informational purposes only.

A1. Introduction

pinch points created by moving parts of the welding

machine or should provide protection against the hazard.

This annex covers many of the basic elements of safety

pertaining to friction welding processes. The hazards that
may be encountered and the practices that will minimize
personal injury and property damage are reviewed here.

A2.3 Power-Clamping Work-Holding Devices

A2.3.1 Friction WelderLack of Pressure in
Clamp Side of Actuator When Starting Rotation.
Where a lack of pressure on the clamp side of the actuator can result in a foreseeable risk of injury, powerclamping devices should be provided with an interlock
safeguard to prevent injury to the operator. The interlock
should prevent rotation of the workpiece until adequate
pressure is detected in the clamp side of the actuator.
Exception: jogging the spindle in a manual mode may be
permitted.

A2. Equipment Safety

A2.1 Responsibility
A2.1.1 Manufacturer. It should be the responsibility
of the welding machine manufacturers to design and construct their equipment in compliance with national and
local safety standards as well as the applicable portions
of this specification.

A2.3.2 Power Loss to Work-Holding Devices.

When power is required to maintain clamping force and
where failure of such power presents a hazard to personnel due to accidental release of the workpiece, a method
should be provided to either safely contain the workpiece
or to safely stop the machine while maintaining sufficient clamping force to hold the workpiece.

A2.1.2 Reconstructor or Modifier. It should be the

responsibility of any person reconstructing or modifying
a FRW or FSW machine to do so in compliance with
national and local safety standards as well as the applicable portions of this specification.

A2.3.3 Unclamping a Workpiece. Where unclamping the workpiece will result in a hazard to personnel, a
method should be provided to prevent unclamping while
the workpiece is being power driven. The unclamp control should be protected from unintentional operation.

A2.2 Inherent Hazard Protection

A2.2.1 Power Transmission Components. The manufacturer should eliminate any hazard associated with
power transmission components by design or should provide protection against the hazard in accordance with
ANSI B15.1, Safety Standard for Mechanical Power
Transmission Apparatus. Where the hazard cannot be
eliminated by design or protection, the manufacturer
should warn against the hazard by affixing a permanent
warning sign or label in accordance with ANSI Z535.4,
Product Safety Signs and Labels.

A2.4 Anti-Motion Mechanisms or Counterbalance on

Slide Mechanisms. All new or reconstructed welding
machines should be provided with an anti-motion mechanism or counterbalance system to prevent or retard
unintended movement of the slide mechanism.
A2.5 Tool Retention. Cutting tool systems should retain
the cutting tool during the machining cycle. These mechanisms should not release as a result of power loss.

A2.2.2 Pinch Points Due to Welding Machine

Movement. The manufacturer should eliminate the

A3.2.4 Chips and Flash. A permanent safeguarding

means should be provided when necessary to prevent
chips and flash from being thrown on the operator, the
operators work area, or other assigned work area or
aisle. Chips should be removed by the use of a tool,
puller, brush, or shovel.

A2.6 Hazards Involved with FRW/FSW

A2.6.1 Hot Parts. Welded parts are heated locally to
temperatures near the melting point. Subsequent heat
redistribution (particularly in aluminum and copper
alloys) can cause general heating of the part and fixtures
to the point where, as with any welded parts, appropriate
handling precautions should be taken.

A3.3 Safety Apparatus

A2.6.2 Hazardous Vapors, Dusts, and Fumes.

FRW/FSW generates high temperatures which may cause
the formation of metal vapors, fumes, and dusts. Consideration should be given to ventilation requirements.

A3.3.1 Fixed Guards. Fixed guards used to satisfy the

requirements of this standard should do the following:
1. Prevent entry of parts of the body into the hazardous areas being guarded;

A2.6.3 Flash Removal. The chips resulting from friction weld flash removal are extremely hot and should be
handled with caution. It is not safe to handle the chips
immediately after they are produced with gloves alone.

2. Create no pinch points between themselves and

moving parts of the welding machine or tooling;
3. Be securely attached to the welding machine
frame, component, or fixture, and utilize fasteners not
readily removable by the operator.

A3. Personnel Safety

A3.3.2 Movable (Interlocked) Guards. Movable

guards used to satisfy the requirements of this standard
should do the following:

A3.1 Responsibility. It should be the responsibility of

the employer to provide and ensure the usage of safety
apparatus, required by the subsequent portions of this
section, as long as the apparatus itself does not create a
hazard.

1. Movable guards should be interlocked with the

welding machine to prevent machine cycle actuation
until the guards are correctly positioned;

A3.2 Hazard Protection

2. Movable guards should prevent entry of operators

body into the hazardous areas being guarded;

A3.2.1 Point-of-Operation Hazard. The point of

operation on welding machines should be safeguarded.

3. Movable guards should create no pinch points

between the guards and other stationary or moving parts
of the welding machine or tooling;

A3.2.2 Loading and Unloading Power-Operated

Work-Holding Devices. When power-operated workholding devices have clearance 1/4 in [6 mm] or more
from the surface of the workpiece to be gripped, a means
should be provided to protect the operator.

4. Movable guards should contain an interlock

arranged so that the welding machine cannot be accidentally actuated.

A3.2.3 Tool-Trapping Space. Tool-trapping space is

space in which motion other than welding takes place,
such as, but not limited to, slide advance, head stock
advance, jaws clamping, shear tool motion, or tool slide
motion if flash turning is employed. A safety apparatus
should be required for welding machines when operating
in semiautomatic or automatic cycles and when any
motion is not directly controlled by the operator. There
are two exceptions:

A3.3.3 Other Interlocks. Interlocks used to satisfy

the requirements of this standard should protect the operator by one or more of the following:

1. The operator is effectively protected by his or her

position relative to the tool-trapping space, and assured
by such as space restraints on the operator or a continued
presence switch (light curtains or pressure-sensitive
mats).

3. Stopping the machine cycle by use of a presencesensing device that actuates if the operator's hand or
other part of the body enters the area that this device is
designed to protect.

1. Requiring the concurrent application of both of the

operator's hands to the machine controls until the hazard
being protected against is no longer present;
2. Establishing the operators position so that the
body is excluded from the hazardous area;

A3.3.3.1 Presence-Sensing Guarding Device. A

presence-sensing guarding device, when used, should be
interlocked into the control circuit to prevent or stop
machine motion if an operators hand or other part of the

2. The welding machine operates in a manual or setup

mode, and each motion is controlled step by step by the
operator.
8

body is detected in the sensing field of the device. The

device should meet the following requirements:

instructions, procedures, and training set forth by the

employer to meet the requirements of this standard.

1. It should not create any hazard to the operator;

A4.4 Installers Responsibility. It should be the responsibility of the person(s) installing a welding machine to
use procedures that will allow for a safe installation.

2. It should not be used as a cycle-start mechanism;

3. It should be designed to fail-safe so that failure of
the device power source, excessive ambient light, temperature variations, or other environmental factors
should not adversely affect the protection offered to the
operator.

A5. Safe Use

A5.1 Machine Manufacturer Responsibility. For each
new welding machine, the machine manufacturer should
provide an operations manual.

A3.3.3.2 Two-Hand Control. A two-hand control

should meet the following requirements:

A5.2 Machine Modifiers or Reconstructors Responsibility. The modifier or reconstructor of the machine
should provide an operations manual for the machine as
modified or reconstructed.

1. It should have the individual operators hand controls protected against unintentional operation;
2. It should have the individual operators hand controls arranged by design and construction, or separation,
or both, to require the use of both hands to initiate the
welding cycle;

A5.3 Employer Responsibility

A5.3.1 Supervision. The employer should ensure
by supervision that safe operating procedures are being
followed.

3. It should use a control arrangement requiring

concurrent operation of the individual operator's hand
controls.

A5.3.2 Work-Driving and Holding Equipment. It

should be the responsibility of the employer to provide,
maintain, and enforce the use of work-driving and holding equipment that is of adequate size, capacity, and condition to perform the type of operation required on the
welding machine. The gripping member (jaws) are subject to wear and damage during use and, as such, can
become ineffective in holding the workpiece. Periodic
inspection and maintenance should be performed to
ensure that proper gripping ability is maintained.

A4. Safe Use, Care, Installation, and

Maintenance
A4.1 Manufacturers Responsibility. It should be the
responsibility of the manufacturer to provide instructions
for the safe use, care, installation, and maintenance of the
welding machine. For a product with unique characteristics, specific instructions should be provided.

A5.3.3 Setup. The employer should ensure that only

trained personnel are permitted to perform welding
machine setups.

A4.2 Reconstructors or Modifiers Responsibility. It

should be the responsibility of any person(s) reconstructing or modifying a machine to provide instructions for
the safe use, care, installation, and maintenance of the
machine as modified.

A5.3.4 Operations Manual (Employer). For all

welding machines, the employer should make the operations manual available to individuals setting up or
operating the welding machines.

A4.3 Employer Responsibility. It should be the responsibility of the employer to maintain the welding machine
in safe operating condition. Maintenance personnel
should follow safe practices in maintaining the welding
machine.

A5.3.5 Instruction of Employees. The employer

should ensure that training and instruction for setup
personnel, operator, and helpers in the safe method of
performing any operation on the type of welding
machine used occurs before the employee(s) will be able
to operate or setup.

A4.3.1 Maintenance Manual Availability. The

employer should utilize any pertinent information contained in the maintenance manual provided as a part of
the information made available to maintenance personnel
for new welding machines and for those modified or
reconstructed.

A5.3.6 Safety Instructions. Special emphasis should

be placed on instructing inexperienced employees
concerning hazards involved in the following areas of
welding machine operation.
A5.3.7 Personal Protective Equipment. The
employer should determine what personal protective

A4.3.2 Maintenance Personnel. The employer

should ensure that maintenance personnel follow the
9

equipment is needed when operating friction welding or

friction stir machines and should enforce the proper use
of this equipment.

ators, helpers, or setup persons responsibilities include

the following:
1. Follow all safety practices and procedures given in
this specification that apply to their actions and conduct;

A5.3.8 Work Area. Provision should be made for the

safe storage and handling of tooling and parts that could
dislodge and fall, or roll. The floor area of the operator's
work position should be cleaned to prevent oil, grease,
and chips from accumulating in order to prevent a
hazardous condition.

2. Notify the supervisor when an unsafe practice or

condition is observed;
3. Properly use all personal protective equipment as
specified by the employer;

A5.3.9 Overloading. The employer should require

that all welding machines and auxiliary equipment be
operated within their safe capacity ratings as specified by
the manufacturer, modifiers, or reconstructors.

4. Install, position, or adjust safety devices as

instructed by the employer under the provisions of this
standard;
5. Do not alter, remove, or disable any safety equipment without the approval of the employer;

A5.3.10 Guards, Devices, Awareness Barriers,

Awareness Devices, and Shields. It should be the
responsibility of the employer to ensure that all guards,
devices, awareness barriers, awareness devices, and
shields are in good condition and in place during operation of the welding machine.

6. Make a visual safety check of the setup during

each shift. Severe operating conditions should require
more frequent checking;
7. Do not wear clothing or jewelry that will present a
hazard to their personal safety;

A5.4 Employee Responsibility. The employee should

follow the instructions and directions set forth by the
employer to meet the requirements of this specification.
Examples of the welding machine operators, setup oper-

8. Maintain an orderly work area. Particular attention

should be given to the storage of tools or parts that could
be dislodged and fall, or roll.

10

This annex is not a part of AWS C6.2-2006, Specification for Friction

Welding of Metals, but is included for informational purposes only.

4. American Welding Society, 1998, Safety and

Health Fact Sheets, 2nd ed., Miami: American Welding
Society.

1. American National Standards Institute (ANSI), 2001,

American National Standard for Machine Tools-LathesSafety Requirements for Construction, Care, and Use, B11.62001, New York: American National Standards Institute.

5. International Organization for Standardization,

2000, WeldingFriction welding of metallic materials,
ISO 15620:2000, Geneva: International Organization for
Standardization.

2. American National Standards Institute (ANSI),

2002, Product Safety Signs and Labels, Z535.4-2002,
New York: American National Standards Institute.
3. American National Standards Institute (ANSI), 1994,
Safety Standard for Mechanical Power-Transmission
Apparatus, B15.1-1994, New York: American National
Standards Institute.

6. OBrien, R. L., ed., 1991, Friction Welding, Vol.

2 of Welding Handbook, 8th ed., Miami: American
Welding Society.

11

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12

This annex is not a part of AWS C6.2/C6.2M:2006, Specification for Friction
Welding of Metals, but is included for informational purposes only.

13

Welding Procedure Specification

Direct-Drive Friction Welding
Date
Welding Procedure Approved by

Requalify on

Customer
Part/Name/Number

Welding Machine
Make
Model No.
Serial No.

Location
Effective Weld Cylinder Area (specify
units)
Part Dimensions at Weld Area
Rotating Part

Stationary Part

Joining Design (bar-to-bar, tube-to-tube, etc.)

Overall Initial Part Length (specify units)
Outside Diameter at Weld (specify units)
Inside Diameter at Weld (if tube) (specify units)
Plate Thickness if Applicable (specify units)
Material Type/Specification
Bonding Surface Hardness (specify units)
Part Stick Out from Tooling (specify units)
Machine Parameters
Primary Control

Distance

or

Time
Spindle
(RPM)

Force
(specify units)

Time
(specify units)

Required
Preheat (1st Friction)
Heat (2nd Friction)
Forge Delay
Upset (Forge)
Upset (Forge) Hold Time
Optional
Spindle Clamp Pressure
Fixture Clamp Pressure
Brake Force
Brake Delay Prior to Upset
Minimum Time to Reach Upset Force
Preweld Butt Length
Minimum
Maximum
Total Cycle Time
Minimum
Maximum
Total Loss of Length
Minimum
Maximum
Finished Length
Minimum
Maximum
Flash Trim
Postweld Heat Treat
Yes
No

If yes, attach procedure specification.

Form C1Weld Procedure Specification (WPS) Example

for Direct-Drive Friction Welding Procedure Specification
14

Distance
(specify units)

Welding Procedure Specification

Inertia-Friction Welding
Date

Requalify on

Customer

Welding Procedure Approved by

Part/Name/Number
Welding Machine

Make

Location

Model No.

Effective Weld Cylinder Area (specify

units)

Serial No.
Part Dimensions at Weld Area
Rotating Part

Stationary Part

Joining Design (bar-to-bar, tube-to-tube, etc.)

Overall Initial Part Length (specify units)
Outside Diameter at Weld (specify units)
Inside Diameter at Weld (if tube) (specify units)
Plate Thickness if Applicable (specify units)
Material Type/Specification
Bonding Surface Hardness (specify units)
Part Stick Out from Tooling (specify units)
Machine Parameters
Required
Spindle Rotational Speed (RPM)
Total Inertia (Spindle, Tooling, and Flywheel Mass) (specify units)
Weld Force or Pressure (specify units)
Cooling Dwell Time (specify units)
Optional
Upset Speed (RPM)
Upset Force or Pressure (specify units)
Spindle Clamp Pressure (specify units)
Fixture Clamp Pressure (specify units)
Total Cycle Time (specify units)
Minimum
Maximum
Preweld Butt Length (specify units)
Minimum
Maximum
Total Loss of Length (specify units)
Minimum
Maximum
Flash Trim (Spindle RPM and/or Force) (specify units)
Postweld Heat Treat

Yes

No

If yes, attach procedure specification.

Form C2Weld Procedure Specification (WPS) Example for Inertia Friction Welding
15

Welding Procedure Specification

Friction Stir Welding
Date

Requalify on

Customer

Welding Procedure Approved by

Part/Name/Number
Welding Machine

Make

Location

Model No.

Tool Design Reference No.

(attach tool drawing)

Serial No.
Part Dimensions at Weld Area
Joining Design (butt, T, lap, etc.)
Overall Part Length (specify units)
Material Type/Specification
Machine Parameters
Primary Control

Position

or

Force
Rate
(specify
units)

Spindle
Speed
(RPM)

Time
(specify
units)

Distance
(specify
units)

Maximum
Force
(specify
units)

Required
Plunge
Dwell after Plunge
Travel Speed
Dwell at End of Travel
Optional
Postweld Heat Treat

Yes

No

If yes, attach procedure specification.

Form C3Weld Procedure Specification (WPS) Example for Friction Stir Welding

16

Welding Procedure Specification

Quality Control Production Sampling
Frequency

Yes/No

Time (specify units)

Every X Pieces

At Machine Startup
If Machine Idle for
Test After X Pieces or X Time
Test Sample to be Retained

Test Data Requirements

Test Type

Acceptance Criteria
(use space below, if needed)

Yes/No

Metallographic
Bend Test
Tension
Other Mechanical (Define)
NDE

Test DataFurther Information

(insert additional data required by user)

Joint Design Schematic

(insert sketch or drawing of the joint detail)

Form C4Weld Procedure Specification (WPS) Example for Production Sampling

17

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18

- This annex is not a part of AWS C6.2/C6.2M:2006, Specification for Friction
Welding of Metals, but is included for informational purposes only.

D1. Introduction

along with the edition of the standard that contains the

provision(s) the inquirer is addressing.

The American Welding Society (AWS) Board of Directors

has adopted a policy whereby all official interpretations
of AWS standards are handled in a formal manner.
Under this policy, all interpretations are made by the
committee that is responsible for the standard. Official
communication concerning an interpretation is directed
through the AWS staff member who works with that
committee. The policy requires that all requests for an
interpretation be submitted in writing. Such requests will
be handled as expeditiously as possible, but due to the
complexity of the work and the procedures that must be
followed, some interpretations may require considerable
time.

D2.2 Purpose of the Inquiry. The purpose of the

inquiry shall be stated in this portion of the inquiry. The
purpose can be to obtain an interpretation of a standards
requirement or to request the revision of a particular provision in the standard.
D2.3 Content of the Inquiry. The inquiry should be
concise, yet complete, to enable the committee to understand the point of the inquiry. Sketches should be used
whenever appropriate, and all paragraphs, figures, and
tables (or annex) that bear on the inquiry shall be cited. If
the point of the inquiry is to obtain a revision of the
standard, the inquiry shall provide technical justification
for that revision.
D2.4 Proposed Reply. The inquirer should, as a
proposed reply, state an interpretation of the provision
that is the point of the inquiry or provide the wording for
a proposed revision, if this is what the inquirer seeks.

D2. Procedure
All inquiries shall be directed to:
Managing Director
Technical Services Division
American Welding Society
550 N.W. LeJeune Road
Miami, FL 33126

D3. Interpretation of Provisions of

the Standard

All inquiries shall contain the name, address, and affiliation of the inquirer, and they shall provide enough information for the committee to understand the point of
concern in the inquiry. When the point is not clearly
defined, the inquiry will be returned for clarification. For
efficient handling, all inquiries should be typewritten and
in the format specified below.

Interpretations of provisions of the standard are made by

the relevant AWS technical committee. The secretary of
the committee refers all inquiries to the chair of the particular subcommittee that has jurisdiction over the portion of the standard addressed by the inquiry. The
subcommittee reviews the inquiry and the proposed reply
to determine what the response to the inquiry should
be. Following the subcommittees development of the
response, the inquiry and the response are presented to
the entire committee for review and approval. Upon
approval by the committee, the interpretation is an official

D2.1 Scope. Each inquiry shall address one single provision of the standard unless the point of the inquiry
involves two or more interrelated provisions. The provision(s) shall be identified in the scope of the inquiry

19

be obtained only through a written request. Headquarters

staff cannot provide consulting services. However, the
staff can refer a caller to any of those consultants whose
names are on file at AWS Headquarters.

interpretation of the Society, and the secretary transmits

the response to the inquirer and to the Welding Journal
for publication.

D4. Publication of Interpretations

D6. AWS Technical Committees

All official interpretations will appear in the Welding

Journal and will be posted on the AWS web site.

The activities of AWS technical committees regarding

interpretations are limited strictly to the interpretation of
provisions of standards prepared by the committees or to
consideration of revisions to existing provisions on the
basis of new data or technology. Neither AWS staff nor
the committees are in a position to offer interpretive or
consulting services on (1) specific engineering problems,
(2) requirements of standards applied to fabrications
outside the scope of the document, or (3) points not
specifically covered by the standard. In such cases, the
inquirer should seek assistance from a competent engineer experienced in the particular field of interest.

D5. Telephone Inquiries

Telephone inquiries to AWS Headquarters concerning
AWS standards should be limited to questions of a general nature or to matters directly related to the use of the
standard. The AWS Board of Directors policy requires
that all AWS staff members respond to a telephone
request for an official interpretation of any AWS standard with the information that such an interpretation can

20

- -
Designation
C6.1/C6.1M

Title
Recommended Practices for Friction Welding

21

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22