Inertia Friction Welding Demonstration - Manufacturing Technology, Inc.
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- เผยแพร่เมื่อ 28 ก.ย. 2024
- Advantages and Benefits to Rotary Friction Welding:
The machine-controlled friction weld process, as shown here, is consistent and reliable, eliminating human error while producing weld quality that is independent of an operator’s skill level. The process parameters are easily controlled, repeatable, and monitored, allowing for real-time and statistical monitoring of the parameters.
Rotary Friction Welding also creates a 100-percent bond of the contact area - such as a full-section weld around a diameter on the OD or ID of a tube - creating joints of forged quality. The weld properties are superior to welds created with fusion processes, such as MIG or TIG welding. This results in a higher strength bond and greatly increased design flexibility of part.
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I was expecting to see them remove the excess and reveal a clean look of the single welded part!
Disappointed. But still a cool thing to see.
Where can I get this soundtrack?
Aperture Science.
ShiroiKage009 Sup.
ShiroiKage009 win!
I wonder the same thing. It sounds like the music from the muffin monster grinder video. Same source?
Imagine putting your hand in the middle of the weilding! THAT WOULD HURT!!!
The biggest advantage is that inertia welding can join two completely different metals together! It is the only high-strength method of doing this, other methods for joining dissimilar metals such as brazing are magnitudes weaker. This is actually why the process was invented. Caterpillar needed to join dissimilar metals together for the exhaust valves of their Million Mile Motor. Heat-resistant but brittle metal for the head and a more malleable, better-wearing metal for the stem.
Heat + pressure creates energy exponentially, simple and effective.
Explosive welding can do the same thing too, though much for expensive and at much greater extent.
One of the work pieces has a large mass (flywheel) attached to it - they spin it to a predetermined rotational velocity before disengaging the motor and pushing it into the second (fixed) work piece. The energy stored in this rotating mass is transformed into frictional heat at the interface of the two pieces of metal.
Finally, there is another welding video that will get recommended to everyone when the algorithm breaks!
I have to say is this video is pretty cool, just like the job I do everyday. MTI Friction welder operator. Excuse me for being so proud!
This music is absolutely 100% from a 1979 porno movie with Peter North, yikes. But friction welding is like metal porn, so it fits perfectly.
very impressed that you knew that.
it fits perfectly, i like the pun
lol
@@reecezosche1886 "Bow chicka bow wow." - Tucker, RvB
Darude - Sandstorm
Beautifully put. This is clearly stated in the narration and visually with the footage, but presumably some viewers must have missed that. Great video by the way. Quite hypnotic. Thanks for sharing. :-)
Awesome display. The beauty on this is that it would be a complete through weld, not jus the lip. Thanks for posting this.
Well that was the most surprisingly entertaining minute I've found on TH-cam in a long time!
As a child, this is how i imagined gay sex worked
One man spins around on an axle at several thousand RPM before being forced against the other? x'D
Colonel Crow Clearly. Are you saying it isn’t????
A relatively low tech concept delivered with repeatable results/tolerances from a high tech equipment interface. Well presented.
I really like this video. I'm going to further research heat from friction for the possibility of maintaining 600 degrees Fahrenheit to 700 degrees Fahrenheit for the vapor system I'm working on. Thank you for posting this video up. I also learn about this technology on the television series Modern Marvels.
Seriously, great demo and I have about a dozen followup questions...
but the 4:3 ratio and 90's soundtrack tell me the only way I'm going to get them answered is if I call to "request a quote" circa 1996
This is simply amazing, human ingenuity has come so far...
So once its done you machine off the proud parts to make a solid bar again and the join is as strong as the parent metral?
This is the best music I have heard ALL DAY
I ran a friction welding machine at a plant that produces airbag inflators for the automotive industry. Load the parts into the machine and in a few seconds it would spit out a perfectly welded component. Then a robot arm would grab it, place it onto a lathe to remove the bead material, and you'd have a vessel that would hold around 5,000 PSI.
thats a good question, i think its because the spinning metal rotates sort of inside it so till it stops the molten metal isnt actually making contact to fly off, second it starts to cool it compresses and, well, bonds i guess
This a very good way of bonding dissimilar materials the bond if done properly is stronger than the original material. we used it a lot on our gas turbine engines.
It's very cool, but the weld line looks so messy... is there a way to chip off the excess and maintain the integrity of the join?
If I were to then turn that shaft down to it's original OD, would the joint be visible?
It says in the video that one is held stationary while the other one rotates so basically im guessing one is suppose to keep it from flying off.
Why does the bonding happen right before the rotary piece stops moving as opposed to right after? It seems to me that bonding would be much harder when one piece is moving.
What is the difference between friction welding processes with continuous drive and friction welding processes with inertia?
In inertia type the drive to the flywheel is removed when it reaches its max rpm and welding is done by momentum ie inertia.
While in continuous the drive to flywheel is their till end of welding.
@dougw246 a forged joint..i have never come across that terminology before... thanks for clearing it up for me..
This is oddly satisfying.
This technology is much older than that...it was developed back in the mid-1950s.
The music makes it look like a comertial 😂
I'm a little confused. The piece of metal appears to be spinning really fast, and it would need to to make that much friction. My question is, why doesn't the molten metal fly off when it's spinning?
Is the weld as strong as the surrounding metal,how about adding little round disc's, of different alloys into the mix to make a stronger weld,joint?
What exactly makes this type of welding useful? and... omg, how much work is it to clean those welds up? i mean with the steel bulging out like that?
Have you ever tried 300 stainless or 300 grades of stainless to steel? If I weld 304 to 1018 I need 309,312 or inco82 filler. Can your process eliminate the need for those costly filler metals? Do you have any trouble with grain structure? I would really like to talk to you! Pure Genius. Thanks for the great video show us more. Have you ever tried buttering dissimilar joints? How good does that weld look on X-ray? Have you ever tried to form a seal and use purge gas? Loads of potential.
Are you guys going to IMTS 2012?
So do you calculate how fast to spin the flywheel based on materials and type or what?
This is just a demonstration like it says at the start. But, you would probably friction weld 2 pieces of steel that are slightly dis-similar, or maybe one is a complex machined part, the other just a short splined shaft. Or maybe one has been heat-treated (an expensive process) and the other hasn't.
Many cars/trucks now have stuff like this in the automatic transmissions. Rear-axle housings for big tractor trailers are done like this to weld on the ends.
that's super cool, but it looks rather messy. maybe they cut off the extra afterward?
Does this method change the structural integrity of the area?
why are they cutting the pieces apart in the first pace?
i always thought the machine was stopped using awesome brakes. because i would imagine that the momentum of the flywheel would break the weld as it was still in the cooling process:P awesome video;)
what happens if you rotate both parts ? But in different directions of curse.
WOW 'm impressed!
I want same brakes in my car :D
It would be nice to see the finished product/application.
Other than welding metals together, could this device be used for research purposes, such as finding the coefficient of friction between two surfaces?
Of course
ah, I see. so the flywheel size has to be varied?
@treblen12 Not only that, but you can join two different metals. As far as I know, the valves in your car's engine are made this way because the metal at the valve seat and the metal that hits the cam need to have different material properties
Because every important industrial, aerospace... (etc.) development in this world is released, studied, tested, studied, tested and so on 20-30 years before you hear something about it.
And I say 20-30 years meaning in general terms. Some can take shorter (much shorter), or longer... ^^
Development competition, and prototypes/ideas keept in "the secret box" for the future, my friend.
how do u take off that excess metal that cover the conjunction?
wouldnt you have to anneal this afterwards?
Would a weld like this be applicable to a cars axle's?, for example if i want to shorten them, or add a small piece into them to make them longer?
How much stronger is that than tig or arc? I know they are both different but just wondering
is it possible to friction weld an aluminum to stainless steel?
@Knnniggit I think you're on to something. You can keep spinning the flywheel faster and faster, even with a puny energy input, if you are patient enough to wait for it to come up to speed. Then, you "dump" all that stored energy (stored in the rotational energy of the flywheel) into the parts to be welded, all of a sudden. Lotsa heat, right away.
Do you use shield gas for this procedure?
What if we put two opposite spins
This is awesome, but what would you use that on?
the world wouldnt be the world we see today if it wasnt for it
wow how much pressure are we talking about?
the music is fuckin amazing
my first thought was how the molten metal from the spinning piece doesn't fly around or maybe just expand.
wouldnt it be much better if both metal pieces would spin in the different direction (both in the same dircetion if you understand how i mean it)
Al tener poco radio la velocidad tangencial que tiene es poca por más que tenga alta velocidad, y por eso no se desprende ninguna partícula del material.
Will it blend?
so you melted it together with a big blender? sweet
it is 2 sticks of steel, welded together... isn't it easier just to make one longer stick? i don't understand purpose of this.
ok, i saw now that this is just demonstration :)
what is it used for then?
Could anybody tell me whats the use of inertia welding? I mean in which cases do you use this method instead of other methods of welding or were does it prove to be more eficient?
You can weld big surfaces together very even and precise. Also you only melt the material where its actually joined so you have less thermal influence on the product. And you can join steel and aluminum, which is rather difficult with most other forms of welding and is very important for plane engines for example.
*****
Trust me, I'm an engineeer..ing student. :D
Talon3000 but why would they need to weld it in that way? Those prices were like 200mm each? Couldn't they just get one longer piece like the size needed
newylongboarding
its just a demonstration, no actual workpiece.
... And ? What is the link with friction welding... ?
What does this have to do with inertia?
Brought to you by harbor freight
sz42781 This deserves so many more likes
hey can you explain this three-year-old comment to me? i know what harbor freight is, but what does it have to do with this video?
@@SpaceMissile It has nothing to do with HF
There are hints that this can be done with a drill press. If I want to friction weld 2 brass rods end-to-end on a drill press, what speed does the chuck have to be set to? Do the brass rods have to be a minimum thickness for this to work? Anything else? (like how to stop the motor, or if special cooling of melted joint is required?
Music in a youtube video? How is this not already blocked in Germany?
it needs to slow down at the end to prevent ejection of liquid metal by centrifugal force.
So, you have two 10 inch cylinders that your welding together to make a 20 inch cylinder? Why make the 10 inc cylinders in the first place?
Wouldn't one of them have to be longer? The spinning one is the one losing all the metal
the music makes me wanna wear a pink jumpsuit with glitters and go on an adventure in search of a unicorn
This is ROTARY friction welding, most often seen welding PIPE or TUBING to plate. I'm surprised to see rotary friction welding a SOLID BAR to a plate so easily. Local heating equals linear velocity times local pressure, times coefficient of friction. With tubing, the speed variation is small, so ID moves only a few percent slower than OD. But with a solid bar, its speed tapers all the way down to ZERO at the axis of rotation. The OD moves fastest, so the most heat is generated at the OD, so melting happens first at the OD and the plate under it. After the OD melts, pressure greatly reduces there, so the applied force is redistributed among the remaining unmelted regions, helping them melt faster. But at the center, where velocity is always zero or nearly zero, little or no heat is generated. Melting at the center must be driven primarily by heat conducted from the surrounding material. Linear friction welding might be a better match for welding solid bars to plate.
How strong is such a weld?
full-float style truck axle housings are also made using this process. I'd link a video but I'm not sure how, search youtube for "truck axle friction weld" and watch any of the top 5 results.
How about you do it and tell us what it feels like.
Seems there is no protection for the machine operator. At high speed would it not be possible for the molten metal to cast off? Also, does this method preserve the rotational shear strength of the original metal rod? Perhaps welding together in this manner is efficient, but I'm curious if it alters the metal strength and other properties.
They probably took the guards and shields off for the demonstration.
The molten metal doesn't often go very far at all, if any comes off at all. The most you get hit by is some sparks and sparks don't hurt. If you are worried about strength, just heat up the whole thing really fucking hot, to the point it's soft but won't deform unless you smack it with a hammer, and a piece this large will take a while to heat up that hot all the way through, then just let it cool on its own and it'll be just as strong as if you ordered the right size piece from the mill in the first place. (Or the closest they offer, usually too long and you just cut it down). But in reality, you don't really need shields on something like this. Then again, people have so many shields on lathes and drills that you can't use the fuckers. Where I work, we take them off. Don't put your fingers where you wouldn't put your dick and you won't get hurt.
How accurate can you get with these welds?
That was cool. Gonna go find videos on explosive welding.
You mean thermite?
does it work with glass??
where can i get those machine brakes?
como es eso posible como a k temperatura qeda eso?
I want this job.
But, will it float?
So what's a common part this process applies too I may have seen?
Hi! Thank you for your question! Inertia friction welding is suitable for many applications - most notably, large Aerospace components. A few applications that are welded using Inertia are: Pistons, Engine Valves, Electrical Connectors, and Turbochargers. To see more sample parts, visit: www.mtiwelding.com/parts/?technologies=rotary-friction-welding
@@mtifrictionwelding That is Cool as to see!
Is this a join that is most likely machined away on the final part? I think that is the pain reason I haven't recognized it.
Also does carbon content make this process less viable on some higher content metals? Meaning normally done on parts with lower or no added carbon levels due to higher levels of defects in the manufacturing process?
@@kierenalvarez The flash curl at the weld joint is necessary to machine off for some applications, such as oil pipes, but not always necessary! It depends on the end-use of the product. Also, friction welding is suitable for many materials and many material combinations. Friction welding works with varying levels of carbon content. We have our previously tested and joined material combinations listed on our website here: www.mtiwelding.com/weldable-materials/
was really waiting for Macgyver to pop up cause of the 80s music :DD
But will it blend
That Sir is poetry! What is the diameter of the round stock? How big can you weld? Do you ever have trouble with the cullets spinning on and maring the parts? Sorry I ask so many questions, but I'm fascinated. I weld in a factory If that was beveled properly for me to acheive full penetration with a tig root then tig hot pass then spray mig or stick for fill&cap It would take all day to weld 12 mabey 15! Then they would look like a bananna:) Have you ever tried pipe or tube in that rig?
What do they do with all that sloppy non-contributing metal that oozes out? There ought to be a way to scrape that off or flatten it out. When welding pipes this way, the junk also also sticks out into the pipe, interrupting flow through the pipe.
Yup, scrape it off while hot or mill or grind it off after it cools. The ridge is accessible on the outside, but it's a long reach to get it from the inside. But they seem to just leave it there. The ridge on the inside is substantial and affects flow.
How big of a HAZ is there?
This just what i need for lengthing two drive shafts, 1 11/16'' o/d, are they any companys in the UK?
This music somehow felt VERY nostalgic to me LOL
Agreed
MrMarkpark, traditional welding would be just as strong but this way is way more precise for linging the peices up
sweet
less carbon input im guessing
+Doug W (MTI) well it depends what kind of rod you use so it could be just as strong as this if not more
music makes me so alive! Woo!! go go humans! we can weild everything!
Yeah
That music was so damn catchy I didn't even hear what the guy was saying.
Tip of the day! Buy one piece that is long enough.
dissimilar types of steel,i heard they can even bond diferent metals with this process