Welding With Friction

Welding With Friction
When we examine closely we realize there are minute forces at work. What allows the male cricket to find his mate, or concert halls to be filled with orchestral sounds with every drag of the violinist’s bow, or the batter to slide to home plate, or even skateboarders to manipulate their boards to perform amazing aerial tricks.
Friction, Lubrication, and wear are the key assumptions in which Tribologists study and apply these aforementioned principles. Tribology, a derivative of the Greek word “Tribo” for “I rub” and “ology” meaning “study of” was pioneered in 1493 by Leonardo Da Vinci only to be lost in the annals of history and later rediscovered.
In this segment, our focus will be on the surface imperfections of materials and the interaction of these irregularities. We will take a deep dive and explore how these microscopic defects can create thermal energy when kinetic energy is applied and the application of this transformation in an industrial setting.
Such as the chirps created when the cricket rubs teeth-like ridges on its wings together, or the rosin that give the bow hairs friction when dragged against the violin’s strings, or the batter’s uniform sliding against the infield clay, or the case of the skateboarder gliding his shoes against the rough textured grip tape to execute a kickflip.
Let’s explore inertia friction welding also referred to as spin welding where material held by two chucks are joined together. As you can see one end remains fixed and the rotary forces of the other create enough friction to bond the two ends by capitalizing on the irregularities of their surfaces. Otherwise said, the kinetic energy generated from the rotational motion of one end forces the exterior nuances of the mating surfaces to reach forging temperatures. The mating surfaces achieve enough thermal energy to bond the two ends. This technique is commonly used in the manufacturing of trailer axles, drive shafts and the aerospace industry.
Linear friction welding, much like its spin welding counterpart fuses two surfaces together. However, instead of the axial rotation to generate kinetic energy to achieve forging temperatures used in spin welding. Linear motion is applied to the static end. As a result, linear friction welding is ideal for bonding blades to discs in turbine manufacturing.
The benefits of spin and linear friction welding far outweigh those of traditional fusion welding. The biggest advantage is the cleaning effect the rotary and linear motion has on the mating surface. This is in contrast to fusion welding where oil, wax layers, paint or scale must be meticulously removed to ensure a reliable bond. As a result of this cleaning effect, there is no dependency on inert gases found in traditional welding.
Regarded as the automotive industry standard, ultrasonic welding displaced the former technique of yesteryear. In the past, wire harness connections were spliced and held by terminals dipped in acid and dip-solder. This new standard no longer relies on terminals, acid, and dip-solder but yielded a stronger and reliable bond.
Ultrasonic welding, much like spin welding leverages the irregularities in the surfaces of the bonding materials by creating friction via a horn that vibrates up to 20,000 times a second or 20 kHz by means of acoustic energy. It should be noted that 20 kHz is the upper limit of human hearing. The interaction of these surface inequities coupled with the high-frequency vibration generates enough thermal energy to bond the mating surfaces of the materials. The end result is a durable bond with no dependency on adhesives, fasteners or soldering materials.
A prime advantage of ultrasonic welding is the ability to join molded plastic parts with leak proof joints. For this reason, it has become the application of choice in industries that rely on the bonding of plastics such as the medical industry. Items such as blood/gas filters, dialysis tubing, cardiometry reservoirs, IV catheters and filters, heart sensors for bypass patients, even textiles such as hospital gowns, face masks, and other sterile garments are manufactured utilizing ultrasonic welding.
Friction stir welding has become the method of choice in the locomotive, aerospace and freight industry. Specifically in the production of carriages, fuselage, and containers in which aluminum body panels are seamlessly joined. Superseding antiquated fusion methods friction stir welding eliminates the dependency on consumables such as welding wire, shielding gas, rivets found in other methods. This solid-state process is regarded as environmentally friendly as there is no offing of gases from fumes, rods or wires and because there is no arc lighting, friction stir welding does not have the ocular hazards associated with traditional welding. Mechanical distortion is virtually non-existent due to low surface temperatures which result in high integrity joints with an excellent surface finish.

[@NewMind]

Here’s an interesting follow-up on this subject - kzbin.info/www/bejne/qZ6ufId-abypfM0

[@jackschirmer1]

Where's the rest? I feel as if we were just getting started. This was surprisingly interesting. I want to know more.

[@NewMind]

A follow-up is on its way. Thanks for the support 🙏

[@seasidescott]

yeah, like where do I get a pocket friction welder?

[@melody3741]

Scott B a drill

[@jeffglascock2297]

Solid explanation, good content. I grew up with acetylene, electric arc and pinch welding, along with chemical bonding. A decade ago, or so, I watched my first friction stir welding on a fuselage of the Eclipse 500 aircraft, and later help develop ultrasonic welding processes to bond co-polymers, also in the Aerospace industry. Then thermoforming and thermal bonding processes. Now we’re seeing printing technologies that can construct components without the need for additional welding processes, since they're joined at the molecular level. Amazing at how fast technologies can advance, and we’re only getting started!

[@AdrianHiggins83]

AvE would be proud. Comment for comment sake .

[@NewMind]

Admittedly, we're also fans and subscribers of AvE! Thank you for your continued support of the channel 🙏

[@dreckman69]

Skookem as frick

[@theflannelfisherman8329]

The angle of the dangle is in fact proportionate to the heat if the meat.

[@lehoang3532]

Just a question, what/who is AvE?

[@AdrianHiggins83]

Le Hoang search KZbin

[@MrEazyE357]

"I rub" should've been "to rub". But I just found your channel a few days ago and I'm shocked that you don't have more subscribers. You're killing it with the content. Keep it up and I'm sure AvE will find you soon.

[@NewMind]

Good catch! Thanks for the kind words!

[@robmac3287]

Agree, the content & delivery is outstanding, I’m somewhat addicted to the channel.

[@DynmcStudio]

I now have a new favourite channel. Well done!

[@MisterRorschach90]

I love videos that show the direction the science went in from its roots to what’s being done today. I honestly had no idea friction welding was a thing. It makes so much sense now that I’ve seen it. How many times have I seen metal get red hot when using power tools on it?

[@Strothy2]

One more application of this kind is friction drilling, used for thin wall tubing. The "chip" is forced upwards by the friction and then pressed onto the tube, it makes the thin walls thicker for threads or other applications. If you want to try this at home those tools can be cheaply sourced on eBay or if you have you can regrind old carbides (better get some coffee that could take a while).

[@NewMind]

We kept "friction welding" general because of it's multiple overlapping applications. Interestingly, we're considering a follow-up segment on thermal drilling. Thank you for your input and continued support 🙏

[@alekseysoldatenkov5675]

Holy shit! I love friction even more than I did 7mins ago! This video really helped compress the answers to a bunch of questions I had into one simple explanation. Thanks!

[@YISP7]

I hope this channel will keep up its very special topics. I really enjoy every video so far! Even when i learned several of those topics as a certified metal designer, i barley saw how all this works. Sadly we haven't had access to wonderful video documentaries like this when i graduated years back then :)

[@RodrigoVzq]

This channel is documentary gold

[@zZAPp-fi]

[primitive technology has joined the chat]

[@Dutch_Prepper]

Haha , I noticed him as well

[@andrewbrown6522]

I cant believe how much of this i didnt know. Thanks!

[@clem2usa]

Thank you for the wonderful video! 😊

[@albanopietro3173]

One of the best Welding videos that I've ever seen

[@youtube_fantastic]

Nice work as always. Loved to see the world of friction.

[@councilv1250]

Hey another welding technique you should show is saw welding aka submerged arc welding. It's another form of automated welding that is cool to watch

[@NewMind]

Sounds like a good follow up video 😄 Thanks for your support 🙏

[@hedydd2]

For many decades, JCB the digger manufacturer, has friction welded hydraulic ram eyes to the ram rods. The great advantage here is that the weld is total and not topical and the two parts actually become one part as the metals blend totally.

[@emmitunderwood9502]

there is much more to conventional welding than the torch welding video shown and the use of mig/mag wire and gas welding.

[@moobsmcgee3554]

Excellent video

[@pandaguan]

Now I'm itching for more.

[@Dutch_Prepper]

This is highly interesting. Thanks !

[@daveshaw9344]

Awwww man... I really wish this one was longer

[@johnlemuellipio8044]

Wow, another great channel, keep up the good work, I hope you'll reach many subscribers in a short period of time

[@roger72715]

an underrated channel

[@AdrenalineStew]

I don't think the process of welding plastic parts belongs in the same category of "friction" welding here because friction is not actually its primary mechanism of heating. That's a common misconception even among engineers in the plastics industry. On the machine you show at 4:59, the mechanical wave is perpendicular to the weld surfaces. This means the vibration squeezes the parts, rather than rubbing the parts together (note: rubbing IS how the other ultrasonic welder at 4:28 joins the copper wires which is why the ultrasonic converter is on the side, rather than above the work). The primary heat source for ultrasonic welding of plastic parts is repeated low amplitude, high frequency elastic deformation. You totally can friction weld plastics, but that's not what that machine is doing.

[@kodiak2fitty]

If you are correct, then the people editing Wikipedia are wrong (www.wikiwand.com/en/Ultrasonic_welding). That happens but I tend to trust them. I'd also venture that it is still friction welding since it is going to be a mix of transverse and longitudinal waves. So there is both compression and transverse friction. In addition, if it was simply compression and elastic deformation, the whole part would melt, not just the interface between parts.

[@FallsGaming]

the music was just too much for me. sorry got me on the nerves but I liked it : ) Went Mechanical College and nobody thought Friction welding

[@spacee3249]

Felt like a when a substitute came in for a school day and you had a worksheet to complete with the video

[@iguanaamphibioustruck7352]

Friction welding has been used, to my knowledge, for over 40 years. It was developed from machine shop workers.

[@michaelzlprime]

I'm sold, I want 10 of them!

[@johnuferbach9166]

thanks, really interesting stuff :)

[@LGM4]

game changing!! love it. Plastic welding omg

[@Dumah2007]

0:14 damn he nailed that kickflip + pop shove-it

[@TheDeGhoul]

look again at 0.25x speed. Its actually a 360-flip. Rodney Mullen invented it and when he did it people didn't realise what they were seeing. So he decided to double it. I believe its called the Double Tre flip as showcased here kzbin.info/www/bejne/gom3hayYptx4gtE

[@johanrosenberg6342]

I first heard about it through the 3D-printing community. I've never succeeded at it myself, but apparently you can weld two part with a rotary tool and some filament.

[@headrobotics]

Is the follow up coming?

[@GearQuest]

Great content! Would love a follow-up!

[@iamamiburgunder4826]

i like this.

[@keenheat3335]

wouldn't alignment and fitting tolerance be an issue with friction welding ? since it's vibrating so rapidly

[@HelloKittyFanMan.]

Wow, interesting!

[@kmetze]

I'd never heard of friction-welding. (some) People are so clever!

[@colbyweber650]

i was hoping to hear your take on Friction Stir Welding

[@itsbc753]

Here to help that view/like/comment ratio. You deserve it, always making informational videos!

[@Steyreon]

I say yes to friction welding 👍

[@sefutho]

I nearly thought this was a national geographic television or a planet animal Channel.

[@deathknight02]

2nd one i watched. Subbed right after

[@NewMind]

Thanks for the support!

[@trixrabbit8792]

I’d love to see how the stir welding works.

[@vishalpachpande5921]

It got so disadvantages too... Like 1)sometimes it is possible that the tool gets welded to job. 2) breaking of material is possible.

[@AdrianHiggins83]

Citations??

[@keenanrhode2035]

How is new mind not up there with the legends like Veritasium, Smarter every day, and Mark Roper

[@bobthompson4319]

The wires that were friction bonded... you should take them and "plug" them into eachother and then use a heat shrink on them and then you have a connection that is like a solid wire.

[@redringofdeathgamer]

So, was the guy in the beginning called safe or out?

[@PushyPawn]

"Say goodbye to friction." - KY

[@jaredkennedy6576]

Interesting look at the technology. It's not that new, though, as every truck in my driveway has at least one axle with the tubes friction welded to the center section. The newest is an 85.

[@jason1440]

Friction stir welding is used in modern rocket manufacturing.

[@ipromotedemocracy6777]

I understand MUCH in this video even I don't know much about science it was somehow intersting

[@rob5944]

I thought individual components on cheap disposable items were simply done with heated tool, I didn't realise friction was used this extensively.

[@vencibushy]

You sound like an ultrasonic welding equipment sales rep. The reality is different. At my work we've got both ultrasonic welders and electric spot welders. Each of them has its pros and cons.

[@NewMind]

Did I sell you on the idea atleast? Hahaha The video was an overview of their applications for their respective purposes. Stay tuned for a granular follow up.

[@spencernagle806]

@@NewMind Not sure if you got to the "granular follow up," yet or not. Ultrasonic welding is gaining traction in the manufacture of lithium-ion battery packs for use in hybrid/electric vehicles. Personally, I have used USW to join the cathodes and anodes of multiple lithium-ion cells (consisting of thin copper or thin aluminum tabs) to nickel-plated copper bus bars.

[@dipt_tpid]

2:08 Jonny Giger deck!

[@jthepickle7]

Oh oh. You've got enough here for another two more vids on this subject.

[@SevenDeMagnus]

Cool

[@himssendol6512]

I started from the first us space walk video and went on to watch about vacuum welding and now i’m here. 🤔🤔

[@coryce258]

Welding in space= no electricity, no heat, just clean material. Metals share molecules freely absent of corrosive environment.

[@Lico5512.]

I hate it when the description is the 1st part of the script but I don't know why

[@JK-dv5du]

Great video but the royalty free music gives me 2016 top 10 list vibes 😂😂😂

[@rentiadan1332]

You deserve more subs. Really.. Keep it up and do collab with another channel

[@NewMind]

Thanks for the kind words 🙏 and support!

[@rentiadan1332]

@@NewMind keep it up!!

[@reefchief8]

I did a Tribo when I woke up this morning 👍 for science

[@imreloktu3210]

At first i though i was watching some kind of ad for friction

[@tabaks]

"Using", not "with". Great video!

[@matthewhardwick365]

Why does your voice change so much between episodes?

[@NewMind]

There are two narrators at New Mind.

[@matthewhardwick365]

Ah, I should have assumed such. Great channel by the way, I hope you guys make some bank, I'm not really sure how economically viable KZbin is at the moment.

[@MposhaOfficial]

"What do all these things have in common" Well they are clips in your video

[@randomuser5443]

Friction welding is exactly what happens when I run too hard in my slats

[@zacharytuttle5618]

I feel a little called out as someone who does fusion welding

[@jaysimpson6857]

I’ve learnt little more than welding can be done with friction.

[@4058941]

featured in top 10 videos of the day on walnut.tv/channel/curious

[@raymondg.3173]

Isn't violin resonance?

[@janvanruth3485]

showing the welding of body parts of a car is the wrong example a car body is electrically welded, no friction welding involved

[@Sicktrickintuner]

You are incorrect. I currently build suv’s in a large manufacturer that currently leads the market. The new aluminum hoods are all friction welded. No electricity at all. The braces are put in a holder and a rotary head moves in, and forces the material together in a rotary friction way. It was kinda impressive when I first seen it.

[@janvanruth3485]

@@Sicktrickintuner so i was correct, a car body is not a hood.

[@kodiak2fitty]

​@@janvanruth3485 Given that a modern vehicle cannot pass crash test requirements without the hood, I'd venture it is part of the body. Top hat is still the body.

[@janvanruth3485]

@@kodiak2fitty ever seen a crash test without wheels? so they are part of the body? you have a problem with admitting to be wrong?

[@paintballthieupwns]

@@Sicktrickintuner - Even so aluminum welding does not throw off orange sparks ;) - it was not aluminum welding

[@Mr.Saephan503]

This is why you need foreplay people cause you will friction weld you're self to your partner 😎

[@montylemon9445]

Man imagine that happening Like where do you go from there You're just there, stuck

[@cirlu_bd]

the music is a bit too loud for the voice

[@zevstewart8607]

The video says friction welding, but the music says good morning im Wilfred Brimley and id like to talk to ya today about diabeetus

[@helvet666]

That person needs to clean the rosin off their violin

[@kiwin111]

good video but the music makes it seem more like a febreeze commercial than an informative youtube video

[@post-leftluddite]

Friction Stir Welding is way cooler

[@rossknowles5608]

2 mins in and nothings actually happened yet

[@Neighbour249]

I prefer your new videos, this one just feels like the infamous TV documentary art of saying nothing of import, except a few useless factoids to bring up at the dinner table.

[@executivesteps]

As soon as I hear “deep dive” or “game changer” I’m out.

[@AdarshMadrecha]

Please reduce volume of background music

[@puffinjuice]

Cool topic, but felt more like an ad than a thorough review of the technique. Maybe it was the background track?

[@woundedmonk1884]

That guy needs to clean his violin and stop using so much rosin

[@bubblewang6180]

The receptive week repressingly mourn because week connoly explain versus a overt sweets. rightful, cute ping

[@j5892000]

I dont trust it

[@Guildmanpro]

Friction welding has joint efficiencies higher than your standard fusion welding processes by far. Also much higher fatigue life. source, I am a FSW Expert.

[@j5892000]

@@Guildmanpro oh really? How is that?

[@Guildmanpro]

@@j5892000 Okay, bear with me and get ready for a wall of text. Most of the time when measuring the mechanical strength of a welded butt joint, you will do a pull test. THe pull test will give you a value of a stress in which the sample breaks. good and certified welds will break not in the joint but in the area right next to the joint called the HAZ, Heat affected zone. so why is that? So to answer the question, we have to understand what the HAZ is and how it derives. when you weld 2 pieces of, lets say aluminum together, traditionally you use a torch to input heat into the local area and add a filler metal. whenyou apply heat to the part, the heat will spread though the metal. so the areas neighboring the weld zone will get very hot. Hot enough to begin changing the micro structure. when you apply great amounts of heat to a micro structure, the individual metal grains will begin to enlarge. when metal grains enlarge, your mechanical properties change. normally under these conditions, metal will become 'softer' in this HAZ area, which means your elongation becomes greater, but overall strength decreases. Generally speaking. so the HAZ is the neighboring areas of the weld seam which are mechnically weaker to the rest of the base material. And when stressed, assuming the weld is of good conditions, it will fracture in this HAZ area as noted before. so what does this have to do with the comparison between friction welding processes vs additional fusion welding processes? The answer to that is heat input. for your traditional welding process that require the melting of two materials , a substantial amount of energy needs to be put into a work piece to melt to allow fusion welding to occur. I can't post images in comments but I would ask you look up the phase diagram for Al-Si. assuming you are using a common Al alloy types in automotive, you are looking at melting temps of around 660 C to 760 C to melt. so your fusion welding process will have to locally heat up the weld seam area up to the forementioned temperatures to work. Friction welding process on the otherhand do not need to melt materials. Friciton processes rely on heat and force to produce diffusion bonds along with mechanical mixing (FSW). becasue diffusion does not require the materials to melt to create a joint, but instead added heat (form friction in our case) and high forces, this creates a situation where atoms form the paired metal matrixs to move form one ot the other. When this happens, the paired matrix's intertwine with one another and create a bond, thus diffusion bonding. To put the heat input into perspective for those same aluminum alloys used prior for fusion welding, your needed heat input is drastically reduced from 500C all the way down to 300C. This major difference in heat, the total energy input into the workplace for friction welded products is substantially less. That said, your HAZ is substantially smaller compared to fusion welding and the grains dont grow as much. This results in mechanical properties much closer to the base material prior to welding. therefore, friction welding processes have consistently higher joint efficiencies compared to fusion welding processes. As for Fatigue life, the tldr version would be, friction welding joints, when of quality, have little to no defects compared to fusion welding processes which have a tendency to entrap gasses and oxides. These entrapped oxides and gasses lead to shorter fatigue lives. The smaller HAZ of friction welding processes also plays a large role as well. let me know if you have any other questions, Cheers!

[@LegateMalpais]

Just as overhyped and misunderstood as 3d printing that was supposed to "solve everything" yet it didn't.

[@wickedcabinboy]

Well, once one eliminates all the unrelated content one is left with 5 minutes of visual fluff and uninspired narrative. Meh!

[@PacoOtis]

Why the horrible intrusive music? Best of luck, but this is a rather awful format!