Friction Welding

Introduction
Friction welding (FRW) is considered as a solid-state
welding process that generates heat through mechanical
friction between a moving workpiece and a stationary
component, with the addition of a lateral force called
"upset" to plastically displace and fuse the materials.

Technically, because no melt occurs, friction welding is not
actually a welding process in the traditional sense, but a
forging technique.

Friction welding is used with metals and thermoplastics in a
wide variety of aviation and automotive applications.
Benefits
The combination of fast joining times (on the order of a few
seconds), and direct heat input at the weld interface, yields
relatively small heat-affected zones.

Another advantage of friction welding is that it allows dissimilar
materials to be joined. This is particularly useful in aerospace,
where it is used to join lightweight aluminum stock to high-strength
steels.

Normally the wide difference in melting points of the two materials
would make it impossible to weld using traditional techniques, and
would require some sort of mechanical connection.

.

Welding technique
Spin welding




Explosive welding
Explosion welding (EXW) is a solid state (solid-phase)
process where welding is accomplished by accelerating
one of the components at extremely high velocity
through the use of chemical explosives.

This process is most commonly utilized to clad carbon
steel plate with a thin layer of corrosion resistant
material (e.g., stainless steel, nickel alloy, titanium, or
zirconium).

Due to the nature of this process, producible
geometries are very limited. They must be simple.
Explosion welding:
1- Flyer (cladding). 2-Solidified zone
3- Target (substrate). 4- Explosion.
5- Explosive powder.
Advantages and disadvantages
Explosion welding can produce a bond between two metals that cannot
necessarily be welded by conventional means.

The process does not melt either metal, instead it plasticizes the surfaces of both
metals, causing them to come into intimate contact sufficient to create a weld.

This is a similar principle to other non-fusion welding techniques, such as friction
welding.

Large areas can be bonded extremely quickly and the weld itself is very clean, due
to the fact that the surface material of both metals is violently expelled during the
reaction.

A major disadvantage of this method is that an expansive knowledge of explosives
is needed before the procedure may be attempted. Explosion welding is therefore
far less commonly used than fusion welding alternatives.