ANSI/AWS C6.1-89 (R2009)

An American National Standard

Recommended Practices for Friction Welding

Key Words—Friction welding, direct drive friction

welding, flywheel friction welding, friction forging, inertia friction welding, solid state bonding, spin welding

ANSI/AWS C6.1-89 (R2009)

An American National Standard

Approved by the American National Standards Institute

March 17, 1989

Recommended Practices for Friction Welding

1st Edition

Prepared by the American Welding Society (AWS) C6 Committee on Friction Welding

Under the Direction of the AWS Technical Activities Committee

Approved by the AWS Board of Directors

Abstract

This recommended practice describes friction welding fundamentals and basic equipment requirements. Suggested procedure qualification, inspection methods, and joint designs are detailed. Typical mechanical property data are referenced.

550 N.W. LeJeune Road, Miami, FL 33126

International Standard Book Number: 0-87171-309-8

American Welding Society 550 N.W. LeJeune Road, Miami, FL 33126

© 1989 by American Welding Society

All rights reserved Printed in the United States of America

Reaffirmed: November 9, 1998 and February 24, 2009

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Statement on the Use of American Welding Society Standards

All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of the American National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, or made part of, documents that are included in federal or state laws and regulations, or the regulations of other govern- mental bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by the governmental body having statutory jurisdiction before they can become a part of those laws and regulations. In all cases, these standards carry the full legal authority of the contract or other document that invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS standard must be by agreement between the contracting parties.

AWS American National Standards are developed through a consensus standards development process that brings together volunteers representing varied viewpoints and interests to achieve consensus. While the AWS administers the pro- cess and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or verify the accuracy of any information or the soundness of any judgments contained in its standards.

AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential, or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this standard. AWS also makes no guarantee or warranty as to the accuracy or completeness of any information published herein.

In issuing and making this standard available, AWS is neither undertaking to render professional or other services for or on behalf of any person or entity, nor is AWS undertaking to perform any duty owed by any person or entity to someone else. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the advice of a competent professional in determining the exercise of reasonable care in any given circumstances. It is assumed that the use of this standard and its provisions are entrusted to appropriately qualified and competent personnel.

This standard may be superseded by the issuance of new editions. Users should ensure that they have the latest edition.

Publication of this standard does not authorize infringement of any patent or trade name. Users of this standard accept any and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the infringement of any patent or product trade name resulting from the use of this standard.

Finally, the AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.

On occasion, text, tables, or figures are printed incorrectly, constituting errata. Such errata, when discovered, are posted on the AWS web page (www.aws.org).

Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request, in writing, to the appropriate technical committee. Such requests should be addressed to the American Welding Society, Attention: Managing Director, Technical Services Division, 550 N.W. LeJeune Road, Miami, FL 33126. With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered. These opinions are offered solely as a convenience to users of this standard, and they do not constitute professional advice. Such opinions represent only the personal opinions of the particular individuals giving them. These individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation.

This standard is subject to revision at any time by the AWS C6 Committee on Friction Welding. It must be reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations, additions, or deletions) and any pertinent data that may be of use in improving this standard are required and should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS C6 Committee on Friction Welding and the author of the comments will be informed of the Committee’s response to the comments. Guests are invited to attend all meetings of the AWS C6 Committee on Friction Welding to express their comments verbally. Procedures for appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.

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Dedication

J. O. Bodine

This Recommended Practice is dedicated posthumously to Mr. J. O. Bodine, who, during his technical career, has made a significant contribution to the understanding and use of the friction welding process in production.

J. O. Bodine

This Recommended Practice is dedicated posthumously to Mr. J. O. Bodine, who, during his technical career, has made a significant contribution to the understanding and use of the friction welding process in production.

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Personnel (Reaffirmation)

AWS C6 Committee on Friction Welding

T. J. Lienert, Chair Los Alamos National Laboratory

1. Stotler, Vice Chair Edison Welding Institute

   1. Starks, Secretary American Welding Society

      D. C. Adams Manufacturing Technology, Incorporated

      C. W. Carrier General Electric Company

      J. J. Donohue American Friction Welding, Incorporated

      J. W. Fischer American Friction Welding

      1. A. Knorovsky Sandia National Laboratories

         D. L. Kuruzar Manufacturing Technology, Incorporated

         M. Posada Naval Surface Warfare Center

         J. Price Thompson Friction Welding

         H. W. Seeds AAM

         1. S. Wadleigh Interface Welding

D. J. Walsh Walsh Friction Welding, Incorporated

R. R. Xu Rolls-Royce Corporation

Advisor to the AWS C6 Committee on Friction Welding

J. R. Huber A RD Industries, Limited

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Personnel (Original)

AWS C6 Committee on Friction Welding

D. E. Spindler, Chair Manufacturing Technology, Incorporated

R. B. Leachy, 1st Vice Chair Coatings, Incorporated

C. A. Johnson, 2nd Vice Chair Naval Weapons Center

W. A. Dierschow, Secretary American Welding Society

C. E. Albright Ohio State University

J. O. Bodine (Deceased) Caterpillar Tractor Company

J. B. Bolton DRILCO Division, Smith International, Incorporated

S. B. Carlson New Britian Machine Division, Litton Industries

J. T. Colla Evinrude Motors, OMC

J. O. Cowens Dana Corporation

F. B. Grinsell NEI Thompson Welding Systems

J. R. Kelley General Electric Company

D. L. Kuruzar Manufacturing Technology, Incorporated

J. D. Matyazic Terex Corporation

J. P. Thorne Newcor, Incorporated

W. C. Wright Freight Master Division, Halliburton Company

H. S. Blair* Clark Equipment Company

G. Duchon* University of Wisconsin

J. F. Justice* Productivity Systems, Incorporated

M. T. Pacak* Grant Corporation

R. N. Vecchiarelli* Cindex Industries, Incorporated

F. J. Wallace* Pratt & Whitney Aircraft

K. K. Wang* Cornell University

R. P. Wilson* Chance Collar Company, HOMCO, W. R. Grace, Incorporated

*Advisor

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Foreword

This foreword is not part of ANSI/AWS C6.1-89 (R2009), Recommended Practices for Friction Welding, but is included for informational purposes only.

The Committee on Friction Welding was formed in 1977 with representatives from governmental agencies, industry, and research organizations. The initial objective of the committee was the exchange of friction welding technical infor- mation. As the process gained wider acceptance, it became increasingly apparent that there was a growing need for a set of guidelines to the variations and application of the process.

This recommended practice represents the culmination of committee activity to assemble a summary of friction welding technology into a single source.

This document is intended to serve as a guide for use of the process. Specific applications may require the consider- ation of other factors outside the scope of this document.

This document has been reaffirmed in 2009 and includes errata. A vertical line in the margin indicates a revision from the 1989 edition.

Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary, Committee on Friction Welding, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.

Erratum

The following Erratum has been identified and incorporated into the current reprint of this document.

Page 14, equation in 6.2 was changed from

2 2 2 2

Weld Area = -----WOD-----–---WID- to Weld Area = -----WOD ---–- WID - .

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Table of Contents

Page No.

Dedication v

Personnel (Reaffirmation) vii

Personnel (Original) ix

Foreword xi

List of Tables xv

List of Figures xv

1. Scope 1

2. Definitions 1

3. Measurement 1

4. Process Fundamentals 1

   1. Process Description 1

   2. Process Variations 3

   3. History 3

   4. Process Advantages 3

   5. Process Limitations 3

5. Equipment 8

   1. General Machine Characteristics 8

   2. Direct Drive Friction Welding Machines 8

   3. Inertia Friction Welding Machines 11

   4. Workpiece Restraint 11

   5. Parameter Input Methods 11

   6. Weld Parameter Monitoring 11

   7. Flash Removal 12

   8. Automated Material Handling 12

   9. Angular Orientation 12

6. Joint Design 12

   1. Joint Types 12

   2. Geometry Considerations 12

   3. Other Joint Configurations 14

7. Materials 14

   1. Material Compatibilities 14

   2. Welding Parameters 16

   3. Material Quality Requirements 16

   4. Thermal Treatment of Friction Weldments 16

8. Process Requirements and Applications 17

   1. General Requirements 17

   2. Direct Drive Friction Welding Machines 17

   3. Inertia Friction Welding Machines 18

   4. Applications 18

9. Process Qualification 19

   1. Welding Procedure Qualification 19

      Page No.

   2. Welding Machine Qualification 19

   3. Operator of Automatic Welding Equipment Qualification 19

10. Inspection of Test Methods 19

    1. General 19

    2. Nondestructive Tests 19

    3. Destructive Tests 20

11. Safe Practices 20

    1. General 20

    2. Noise and Hearing Protection 21

    3. Smoke 21

    4. Sparks and Loose Particles 21

    5. Mechanical 21

12. Mechanical Properties of Friction Weldments 22

Annex A (Informative)—Nomenclature and Metric Conversion 23

Annex B (Informative)—References 25

Annex C (Informative)—DVS Part 4, Friction Welding Defects 27

xiv

List of Tables

Table Page No.

1. Nondestructive Examination Techniques and Defect Applicability 20

2. Destructive Examination Techniques and Defect Applicability 20

List of Figures

Figure Page No.

1. Basic Steps in Friction Welding 2

2. Direct Drive Friction Welding Parameter Characteristics 4

3. Inertia Friction Welding Parameter Characteristics 5

4. Modifications of Friction Welding 6

5. Friction Surfacing 8

6. Friction Welding Machine Construction 9

7. Basic Joint Types for Friction Welding 13

8. Friction Weldment Geometry Considerations 14

9. Material Combinations Weldable by Friction Welding 15

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Recommended Practices for Friction Welding

1. AWS standards are published by the American Welding

Society, 550 N.W. LeJeune Road, Miami, FL 33126.