Friction Welding on the Lathe Experiment

Experimenting, we take different types of metal and friction weld them togeather on the lathe , by trial and error i show how i get a good result that bond togeather and stand up to a bend test

[@PS2luvr]

As a machinist, from a safety standpoint I was screaming this whole video. Holding rotating equipment at thousands of RPMs is just plain egregious. Add to that the potential pinch point between your hand and the tool post makes this whole process unthinkable. Please, anyone watching this video, DO NOT replicate the actions this guy took here. The fact that you survived is the truly amazing thing here. This process should ONLY be done with properly rigid holders. AT THE VERY LEAST, use a Jacobs chuck in the tailstock, NEVER your hand. I cannot stress enough how unsafe and terrifying the actions you took are to me. Never should hands be this close to rotating equipment.

[@Wrighmachining]

Yup there is alot going on in that video and dont recomend people try doing as they see in the video.

[@capin232]

This is very interesting, hopefully I get to do some testing before I actually have to use this technique. Keep up the great videos, Brian

[@Wrighmachining]

Let us know what you learn when you do buddy .

[@tpchlu]

The success depends on not only the RPM, but also on the pre heat process, the pressure and time that you push two rods together and the flatness of the surfaces on ends of two rods. Different materials can be welded together easily, either two metals or one metal with one non-metal (plastic).

[@Wrighmachining]

Thank you tpchlu , there are definarly a few variables with tgis process . Plastice ..... i hadnt thought of that . Good point

[@dannywilsher4165]

This is an interesting process. I commented on someone's channel a week or so back about how I had pretty good success with this technique. You were on the same track with the bevel and I think if you would have slowed the pressure on that one like you did on the later ones, it would have worked much better. What I did was drill a small hole in one side and a corresponding size stick out on the other one and use just enough pressure to get lots of heat a good ways back and then get it red and then back off. I found the least pressure I could use but still get the heat worked best for me. I also wanted to cut or grind the piece horizontal (parallel to the rod) to see what was happening on the inside but never got around to doing it...

[@Wrighmachining]

Awesome input Danny thank you , I think I will build off some of your suggestions next time

[@randallsemrau6911]

Brass is self lubricating, maybe thats why it won't friction weld. Isn't that why it's often utilized as material for the nut in lead screw assemblies?

[@Wrighmachining]

Very possible :)

[@shawnmrfixitlee6478]

I gotta try this method .. Been turning for years and have heard of it but you vid explained it best.. new sub here ,, I have a channel as well . Merry Christmas !

[@Wrighmachining]

Glad you enjoyed the video. It takes a bit of playing around to get it to work well. Some guys will put it in the tool post as well. Once it starts to weld it will grab hard. . Just make sure you don't get wrapped into the lathe. :)

[@shawnmrfixitlee6478]

@@Wrighmachining for sure .. I have a live bearing chuck like yours , just a matter of knowing when to let go, thanks

[@eg6sivtec]

Hey there! Great channel ! Subscribed!

[@Wrighmachining]

Thanks jërémi, glad to have you :)

[@bahmanasgari3370]

Good job👍

[@Wrighmachining]

Thx buddy

[@MBTechnicalClasses]

Intrested process

[@Wrighmachining]

It is and has its place on fixing small shafts . Larger would take a higher amount of hp and could be harder on the machine . May try 1 inch at some point but busy with finishing up the summer . Sept will be a big month for mor projects

[@stevesrt8]

That’s pretty cool. Are you just learning or do you have some project in mind?

[@Wrighmachining]

I have the odd job, here and there . Just repaied a delt table saw for a friend that had the 3/8 shaft broken off .

[@wantafastz28]

Nice to see it’s not as easy as others make it to be. What is the minimum hp needed you think?

[@Wrighmachining]

Im not sure th hp . My 3hp lathe you can hear working on the 1/4 to 3/8 stock im guessing say 1 hp min for that size . I would love it if other guys can try it as well and let us know

[@roscoepatternworks3471]

Interesting, have no use for it yet. I wonder if copper would friction weld? Could be that brass is enough of an alloy it won't weld. Good video

[@Wrighmachining]

Maby . My thought was that it was drawing away to much heat. The alum has a much lower melting point and the brass a high point with a hight conductivity. Luck for me i dont work in brass very often . Perhaps i sould try spme copper pipe though

[@Niels_Dn]

@@Wrighmachining I thought the same on the brass.

[@roscoepatternworks3471]

@@Wrighmachining i found this: What metals can be friction welded? Materials Weldable by Friction Stir Aluminium. ... Magnesium. ... Copper and copper alloys. ... Hafnium and zirconium. ... Inconel and superalloys. ... Steel and ferrous alloys. ... Titanium. ... Dissimilar materials.

[@roscoepatternworks3471]

@@Niels_Dn i found a website, may be out of luck on welding brass, due to zinc evaporation.

[@Wrighmachining]

@@roscoepatternworks3471 zink evaporating , awsome idea . Makes sence in a way . Perhaps the zink is drawn out in some way and oxidizes as it decays or evap ? I should test this theory with some copper . If the copper does the same it would be conduction if it welds it would afirm this theory more .

[@tharoncesselli7162]

Did not know this was a thing till now !

[@Wrighmachining]

Pretty dar cool buddy !

[@mitchumsport]

the zinc in the brass is messing with you. its melting out / being pushed out of the contact area I think. some kinds of brass have different content, i.e. some silicon which would make them weld a bit better or differently

[@Wrighmachining]

I like your perspective makes sence

[@jamallwilliams5852]

It’s because brass is softer

[@Wrighmachining]

Very possible , but the alu would weld realy well . One guy sugested flux as an issue . Perhaps more experimenting some day

[@jamallwilliams5852]

@@Wrighmachining would love to see it🙏

[@michaelallen1432]

Try some brazing flux

[@Wrighmachining]

I had not thought of that. Good point

[@IonIon-wc6pc]

Rpm???

[@Wrighmachining]

I did it between 800-1500 rpm. It's takes lots of speed and power