Automotive
engine valve · turbocharger turbine wheel with shaft · cardan and drive shaft · half shaft · steering shaft · shock absorber part · airbag gas generator housing
Applications
Friction welding is a proven process in many fields, from the automotive industry through hydraulics and agricultural machinery to tool manufacturing. It allows parts of complex geometry to be built from simple elements, and materials with different chemical compositions and mechanical properties to be combined within a single part.
Industries
Commercial vehicles and buses
driven axle · trailer axle · brake camshaft · wheel hub · cardan shaft
Railway vehicles
brake system part · axle · linkage
Hydraulics and pneumatics
piston rod · cylinder end cap with eye · rod end with eye and clevis
Agricultural and construction machinery
planetary housing · drive shaft · wheel hub · track roller · hydraulic cylinder
Tool manufacturing
auger drill · milling cutter · reamer · tap · broach · rock drill · tool holder
Electrical and energy
copper–aluminium cable lug · busbar connector · battery connector · copper–steel conductor pin
Refrigeration, HVAC and cryogenics
aluminium–copper tube transition · aluminium–stainless steel tube transition
General engineering
flanged shaft · gear hub · flanged pipe stub
Construction
headed rebar · anchor element
Oil, gas and mining
drill pipe and tool joint · drill rod · corrosion-resistant tube transition · pump part
Further industries
- Pumps and compressors
- pump shaft · compressor part
- Aerospace
- engine shaft · engine disc with shaft · landing gear part · titanium fastener
- Defence
- drive and running gear shaft · ammunition part
- Medical technology
- hip prosthesis stem · surgical instrument
- Nuclear energy
Cost examples
Compared with conventional manufacturing technology.
Agricultural machinery
Tractor planetary housing
−45%
production
cost
cost
Conventional technology
The tractor planetary housing consists of a relatively heavy head and a long shaft. It is conventionally produced by casting or forging. Both processes are labour- and energy-intensive. In forging and casting alike, the relatively long shaft causes difficulties.
With friction welding
The part can be divided into two units: the housing and the shaft. The housing is made of easily forged carbon steel, the shaft of alloy steel because of the higher strength requirement. After welding, the planetary housing is normalised and finish-machined. A planetary housing made this way is equivalent to the forged part in terms of service life.
Engine manufacturing
Crankshaft
−60%
cost compared
with casting
with casting
−48%
cost compared
with forging
with forging
Conventional technology
The crankshaft blank is usually produced by casting or forging.
With friction welding
It can be divided into three parts, which can be quickly produced by cutting from stock.
Tool manufacturing
Cutting tool
−30–40%
material
use
use
Conventional technology
Made from one piece, in high-speed steel (HSS) along its entire length.
With friction welding
The working part of cutting tools is made of high-speed steel (HSS), the shank of carbon steel. Friction welding provides a precise, crack-free joint between the two different steels. The welded tool shows the same edge life as one made from a single piece.
Hydraulics
Piston rod
−20–30%
manufacturing
cost
cost
Conventional technology
The two parts are connected by a threaded or shrink-fit joint.
With friction welding
The working surface is made of hardened or chrome-plated steel, the rear end of softer steel. With friction welding, the two parts can be joined with high precision, and the joint withstands alternating loads better than a threaded or shrink-fit joint.
Automotive
Engine valve
Heat-resistant head, wear-resistant stem
The task
The stem must be wear-resistant, the head heat-resistant.
With friction welding
The two alloys are joined by friction welding. Concentricity, which the process ensures, is particularly important for this part.
Pump manufacturing
Pump shaft
Stainless steel and carbon steel, with different diameters
The task
Only one half of the shaft is exposed to corrosion, and diameter changes are common.
With friction welding
Significant savings can be made by welding cheaper carbon steel, even of a different diameter, to the stainless steel.
Aerospace
Engine disc and shaft
Titanium and nickel alloys
The task
The titanium and nickel-based alloys used in the aerospace industry are difficult to join by fusion welding.
With friction welding
A precise, contamination-free joint is produced, for example between engine discs and shafts.
Request a quote
Send us the part drawing, the material combination and the planned quantity. We assess whether the part is suitable for friction welding and propose how to produce it: by contract friction welding or on a machine adapted to the task. In every case, we validate the process by trial welding.