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The history of the discovery of friction welding: Why does a patent from 1924 have such a lasting impact today?
Friction Welding (FW) is a solid-state welding and joining process that uses mechanical friction between relatively moving workpieces to generate heat. This process applies a lateral force called an upset, which plastically deforms the materials and fuses them together. Friction welding technology is widely used in the aviation and automotive industries and plays an important role in the welding of metals and thermoplastic materials.
"Friction welding is a solid-state welding technique like forging welding, but its mechanism of operation and range of applications are much wider."
History of Friction Welding
Early applications and patents for friction welding date back to the early 20th century, with rotary friction welding being the oldest of the various methods. In 1924, W. Richter obtained a patent for linear friction welding (LFW) technology in the UK, and later H. Klopstock obtained a similar patent in the Soviet Union. Although the initial descriptions were rather vague, these early patents laid an important foundation for friction welding technology.
In 1956, a technician named A. I. Chudikov conducted scientific research on rotary friction welding in the Soviet Union and introduced it as a commercial process for the first time. In 1960, the technology was introduced to the United States, and companies such as Caterpillar Tractor Company, Rockwell International and American Manufacturing Foundry began developing related machines. The development of these patents was not only widely used in Europe and the Soviet Union, but also paved the way for subsequent technological advances.
Mainstream technology of friction welding
Friction welding includes many forms, the following are several main welding methods:
Rotary Friction Welding
In rotational friction welding (RFW), one welding component is rotated relative to the other and pressure is applied. The heating of the material is caused by friction, which ultimately forms an inseparable weld joint.
Linear Friction Welding
Linear friction welding (LFW) involves subjecting one component to a linear reciprocating motion, contacting and applying pressure to a stationary component.
Friction stir weldingFriction stir welding (FSW) is a solid-state joining process that uses a non-consumable tool to join two facing workpieces without melting the material. As the tool moves along the joint line, the heat generated by the friction between the tool and the workpiece material causes the material in the contact area to soften, thereby achieving welding.
Friction surface treatment
Friction surface treatment is a process derived from friction welding whereby the coating material is applied by means of a rotating coating material rod (called a mechtrode) to form a plasticised bonding layer.
Welding quality requirements
The quality requirements for friction welding depend on the field of application, for example in the aviation or flight industry weld defects are unacceptable. Weld quality testing is often performed using measurement and digitization methods to ensure that the alloy or metal has an ultra-fine grain structure.
"The microstructure obtained during friction welding is crucial to the performance of the welded joint."
Technology evolution and future prospects
The evolution of friction welding technology is reflected not only in the diversity of welding methods, but also in the growing number of commercial applications. Since the 1960s, many companies have continued to innovate and develop new hybrid technologies such as low-force friction welding to reduce the force required for welding and improve welding efficiency and quality.
With the development of science and technology, the application of friction welding technology is not limited to metal materials, but has gradually expanded to the welding of thermoplastic materials, injecting new vitality into the future manufacturing industry.
These historical and technological developments clearly show that the influence of friction welding technology is still far-reaching. From the patent in 1924 to the current widespread application, it may lead to continuous innovation and change in the industry in the future. How do you think the future development of friction welding will affect modern manufacturing?
