Friction Welding
Friction welding is a solid phase welding of two similar or dissimilar materials. Using the heat generated by rubbing of two materials and when the impurities at the interfaces are removed as flash, stopping the relative motion of the components and applying a forge welding force to form a strong metallic bond.
Friction Welding
Friction Welding Process
Friction welding is a solid-state welding process used to join similar or dissimilar materials by frictional heat and applied forging pressure. The materials bond without melting, producing a strong and reliable joint.
Hydraulic Friction Welding Technical Specification
| Machine Model | FW 6 | FW15 | FW30 | FW45 |
|---|---|---|---|---|
| Machine Capacity | ||||
| Max Forge Force | 6 Ton | 15 Ton | 30 Ton | 45 Ton |
| Weld Dia | 8 to 20 mm | 15 to 35 mm | 20 to 50 mm | 25 to 60 mm |
| Weld Area Max | 314 mm2 | 950 mm² | 2000 mm² | 3000 mm² |
| Rotating side max Dia and length | 25*200 mm | 40*200 mm | 55*200 mm | 65*200 mm |
| Non-Rotating Side (Dia × Length) | 25*200 mm | 40*200 mm | 55*200 mm | 65*200 mm |
| Spindle | ||||
| Spindle Speed | 2500 rpm | 2000 rpm | 1500 rpm | 1100 |
| Chuck clamping system | T980 Multi bore collet | T980 Multi bore collet | T980 Multi bore collet /Chuck | T980 Multi bore collet /Chuck |
| Self Centering Vice | ||||
| Clamp Force | 10 Ton | 20 Ton | 25 Ton | 35 Ton |
| Clamping cap (min /max) | 10 mm -30mm | 15 mm -50mm | 20 mm -70mm | 25-80 |
| Clamping cylinder stroke | 40mm | 40mm | 40mm | 50mm |
| Main Slide | ||||
| Stroke | 200 mm | 300 mm | 300 mm | 300 |
| Axis Drive | Hydraulic | Hydraulic | Hydraulic | Hydraulic |
| Axis slide | LM Guide ways | LM Guide ways | LM Guide ways | LM Guide ways |
| Power Pack | ||||
| Main Hydraulic power | 5.5kw/440v | 11 kw/440v | 18.5 kw/440v | 22 kw/440v |
| Clamping Hydraulic Motor | 2.2kw/440v | 2.2 kw/440v | 3.7 kw/440v | 3.7 kw/440v |
| Tank Cap | 150lit | 200lit | 250lit | 250lit |
| Controller | ||||
| Control | PLC ,PC Based | PLC ,PC Based | PLC ,PC Based | PLC ,PC Based |
| Machine Power | 16 kva /440v | 32 KVA /440v | 50 KVA /440v | 60 KVA /440v |
| Machine dim (L x B x H ) | 3000 x3000 x 2200 mm | 3500 x3300 x 2200 mm | 3500 x3500 x 2200 mm | 4000 x 3500x 2500 mm |
Optional Accessories
Servo Flash removing slide
Increased bar length stopper
Full Enclose
Program Screen
The friction welding program screen allows the operator to set key input parameters such as spindle RPM, Friction/forge load (force), and friction/forge time in seconds.
During the welding cycle, the machine continuously monitors these parameters in real time to ensure they follow the programmed values based on the selected process sequence.
The system records the actual process data, enabling the operator or customer to review, validate, and fine-tune the parameters for optimal weld quality and repeatability.
Interlocks
An emergency stop switch is provided for all control circuits. Activation of the emergency switch immediately disables all machine operations. Machine commands will not be accepted unless the hydraulic system is activated and pressure is within the operating range.
The spindle cannot be started unless the chucking system is properly engaged and clamped. The automatic cycle will function only when both chuck and clamp are in the ON (clamped) position.
If the lubrication or hydraulic oil level drops below the minimum limit, the machine will stop automatically, and an error message will be displayed on the operator panel. A reset switch is provided to clear faults and re-enable machine operation after the alarm condition is rectified.
