Abstract :

Friction Welding Is A Solid-state Joining Process In Which Two Components Are Joined Through Frictional Heat Generated At The Contacting Surfaces Under Controlled Relative Motion And Axial Pressure. Unlike Conventional Fusion Welding, Friction Welding Does Not Require Melting Of The Base Materials And Can Produce Strong Joints With Relatively Low Distortion And A Narrow Heat-affected Region. This Paper Presents The Design, Fabrication, And Performance Evaluation Of A Laboratoryscale Friction Welding Machine. The Proposed Machine Consists Of A Rigid Machine Frame, Rotating Spindle, Chuck Arrangement, Electric Motor, Belt-drive System, Axial Loading Mechanism, Tailstock/support Assembly, And Control System. The Machine Is Designed To Provide Controlled Rotational Speed, Friction Pressure, Upset Pressure, And Welding Time. The Fabricated System Is Evaluated By Producing Representative Friction-welded Joints Under Different Process Conditions. Weld Quality Is Assessed Through Visual Inspection, Tensile Testing, Hardness Measurement, And Macrostructural Examination. Representative Results Indicate That The Selected Optimum Process Condition Produces A Tensile Strength Of Approximately 465 MPa And A Joint Efficiency Of Approximately 92%, With Acceptable Hardness Variation Across The Weld Region. Increasing Friction Time Initially Improves Joint Quality By Increasing Heat Generation And Interfacial Bonding, Whereas Excessive Friction Time Produces Increased Flash And May Reduce Joint Performance. The Study Demonstrates The Feasibility Of Developing A Compact Friction Welding Machine For Laboratory-scale Joining Of Compatible Metallic Components And Provides A Basis For Further Optimization Of Friction Pressure, Rotational Speed, Upset Pressure, And Welding Time.

Published:

27-12-2023

Issue:

Vol. 23 No. 12 (2023)

Page Nos:

341-355

Section:

Articles

License:

This work is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

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