Rotary Friction Welding

Rotary friction welding is a forge welding process, in which the heat for joining metallic workpieces is generated by a relative motion of two components while a load is applied. It works in the solid phase without reaching the melting point of the materials. Thus, even materials that cannot be joined by fusion welding can be welded. The weld region is normally narrow and shows a refined microstructure.

Relative Motion

Rotary friction welding can be performed in three ways:
  • Continuous drive friction welding
  • Inertia friction weling
  • A combination of the two energy variants.
In continuous drive friction welding, the rotation speed of the component is generated during the friction phase by a continuously driven motor. After the friction time, the relative motion is slowed down and a higher forging force is applied.
In inertia friction welding one of the components is connected to a flywheel, which is declutched from its drive when the right speed is reached. On contact with the workpieces, friction at the weld interface acts both as a heat source and a brake.


Engine valves and gear box lever

Inertia friction welded Airbag inflator

Friction stud welding of aluminium tubes

Contract Manufacturing

As a job shop we manufacuture batches, for which the procurement of a bespoke friction welding machine would not be profitable. Apart from steel-steel connections we can also produce dissimilar material combinations.

Based on our long-term  experience, we develop suitable welding parameters and quality management procedures for friction welding.

Friction Welding Machines

Industrially manufactured friction welding machines are available from several manufacturers and are used commercially at several locations for the welding of cylindrical parts of all kinds.
AluStir conducts feasibility studies or contract manufacturing for you. In the case of high-volume production, we can advise you on machine specifications and machine procurement as well as quality assurance.