42 Welding Technology and Design

explosions are inside the pipe, the noise and environmental problems will be easier
to solve.

Fig. 1.23 Friction welding process

1.2.5.2 Friction welding

Friction between the two welding faces is used to create heat to the extent that
the material at the two surfaces become plastic. Welding is effected by applying
axial force. A schematic diagram of the friction welding process is shown in Fig.
1.23.
The friction welding process is divided into two distinct modes:
(a) conventional drive friction welding, and
(b) inertia welding
In the conventional drive friction welding, the pieces are axially aligned. One
component is rotated at a constant speed by a direct drive while the other is moved
into contact with the former under axial pressure. Sufficient time is allowed for
heat generation, so that the interfacial temperature will make the material plastic
and permit the components to be forged together. At this stage the rotation is
rapidly stopped while the pressure is still maintained to consolidate the joint.
Though the basic principle is the same, in the inertia welding kinetic energy
from a rotating flywheel system is used to heat the faces of components to be
welded. One component will be attached to the flywheel rotating at high speed.
The other component will be brought to face the first, so that friction between the
two will generate heat. The flywheel energy will be utilized to obtain a good bond
between the components.
The principal variables in this process are the relative velocity, heating and
forging pressure and the duration of heating. The secondary factors are pressure
build up during heating and forging, deceleration during braking and the properties
of the material being welded. Peripheral speeds in the range of 75 to 105 meters
per minute appear to give satisfactory welds. Too high a speed may result in a
wide HAZ. Lower speeds will not be able to generate sufficient heat and raise the
temperature upto the required level. The forging pressure depends on the hot