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Operational Steps in Friction Welding and Inertia Welding |
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Operational Steps in Friction Welding and Inertia Welding -
Operational Steps in Friction Welding
(i) The two components to be friction welded are held in axial alignment.
(ii) One component that is held in the chucking spindle of the machine, is rotated and accelerated to the desired speed.
(iii) The other component that is stationary and is held in the movable clamp is moved forward to come into pressure contact with the rotating component.
(iv) Pressure and rotation are maintained until the resulting high temperature makes, the components metals plastic for welding with sufficient metal behind the interface becoming softened to permit the components to be forged together. During this period metal is slowly extruded from the weld region to form an upset.
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(v) When sufficient heating has taken place the power drive is uncoupled, a brake is applied to stop rotation and the axial force is usually increased to forge the two components together. This produces further deformation.
Operational Steps in Inertia Welding
(i) One component is rigidly clamped in a stationary chuck or fixture which has to resist high axial load and torque. The flywheel, with other component chucked in it, is accelerated to the desired angular velocity until it stores enough kinetic energy to produce the weld.
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(ii) At this moment, the drive to the flywheel is cut off and the two components are instantly brought together under high pressure.
(iii) Upon application of this axial force, the weld itself serves to brake the flywheel to rest, converting flywheel kinetic energy to frictional heat and forging action at the weld interface. Axial force is usually maintained at a constant value throughout the weld cycle.
Fibre Flow in Friction and Inertia Welds
The fibre flow lines in the resultant weld area for friction welds are entirely radial as in other forge welds.
Inertia welds exhibit a predominantly circumferential displacement of fibre flow lines which result from forging and flashing the weld zone before rotary motion ceases. This orientation contributes to improved fatigue properties.
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