Experimental evaluation and optimization of friction welding process parameters on similar and dissimilar materials using intelligent techniques

Abstract

In fabrication industry, joining processes play a very important role. Among various joining processes, welding process has more strength as compared to other joining processes. Friction welding is a solid state welding, which is used to join similar or dissimilar materials by applying pressure and without the need of filler materials or additional equipments for heat production. Also, friction welded joints can produce welds that are superior or similar in strength of the parent material. Friction welding enables similar or dissimilar materials to be joined together by sliding one material against the other under pressure. Major advantage of this rotary friction welding is the peak temperature of this process is much lower and thereby allowing a range of dissimilar materials to be welded. This causes a heat due to the friction and the work piece is made into plastic state for joining to occur. Friction welding can join alloys and metals that cannot be welded using other techniques. Since there is no need of additional devices for heat production or filler materials, it is more economical than the conventional welding method. The principal welding variables in the friction welding process includes upset time, upset pressure, heating time, heating pressure and rotating speed. Based on the literature review, the input parameters hold major part in deciding the weld type by varying the input parameters and thus it leads to good weld. Excellent weld quality, high dimensional precision, a small heat affected zone, the absence of filler material, a short welding time and ease of automation for mass production are the main advantages of choosing friction welding. Most of the friction welding joints are made in friction welding machines. In this experimental work, friction joints are carried out by indigenously developed in centre lathe and radial drilling machine. newline