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• Here heat is obtained by the concentrated beam composed
primarily of high velocity electrons.
• As the high velocity electrons strikes the surfaces to be joined, their
kinetic energy changes to thermal energy there by causing the
workpiece metal to melt and fuse.

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fillament

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• 1- Joint preparation
Here the workpiece is closely fitted one. Joint gap is around
0.05 to 0.075mm maximum.
• 2- Workpiece cleaning
Before welding workpiece is mechanical or chemically
cleaned.
• 3- Fixture of workpiece
C- clamps are used to fix W/P. Some time tag weld also
used.

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4- Workpiece demagnetization
Some residual magnetism in the work pieces or fixtures can cause
deflection of electron beam. So W/P is placed in 50 cycle inductive
field.

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5- Pump down:
Vacuum can be produced by Piston Pump or Oil diffusion motors.
The pressure is 10- 4 torr.

6- Preheating the workpiece:

Hardenable and difficult to weld materials need to be preheated.
High strength alloy steels normally more than 9mm is preheated
before electron beam welding.
Torch heating furnace heating induction heating

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• 7- Welding working
• When tungsten filament is electrically heated in
vacuum, it will emit electrons.
• These electrons carry a negative charge which is
passed through the anode hole. The electron beam is
focused by focusing lens.
• When the focused electron beam strikes the w/p, the
kinetic energy of this electron beam is converted in to
heat energy. This heat energy is used to weld the
metals.
• The operation is carried out in vacuum.
• The beams are focussed about 0.25 to 1mm diameter
and the power density of 10 KW/mm2 .
• Aluminium material has focusing length of about 40mm
and steel 30mm.
• Variables are voltage, speed, distance between
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• Advantages:
• High quality weld is produced.
• Deep welding is possible
• Clean and bright weld can be
obtained.
• Disadvantages:
• High cost
• Skilled persons are required
• Limited to small size welding
• Time consuming is high
• Vacuum is necessary

Applications:
• Used to weld titanium, tungsten, molybdenum, SS(stainless
steel), aluminium and many more refractory materials.
• Dissimilar metals can be welded
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• Friction welding is a
solid state joining
process that produces
coalescence by the heat
developed between two
surfaces by
mechanically induced
surface motion.

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 (70 – 140 MPa)

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• Rotational speed
• Heating pressure
• Forging pressure (70 – 140 MPa)
• Heating time
• Braking time
• Forging time
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• The two components to be friction
welded are held in axial alignment.
• One is in chuck and the other one is in the
movable clamp.
• Movable w/p is moved forward to come
into pressure contact with the rotating
component.
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• Pressure and rotation are maintained
until the resulting high temperature
makes the components metals changed in
to plastic condition for welding.
• The applied pressure helps to forge
together.

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AWS Welding Handbook
• Parts to be joined are clamped
firmly.
• A rotating hardened steel tool is
driven into the joint and traversed
along the joint line between the
parts.
• The rotating tool produces friction Butt welds

with the parts, generating enough

heat and deformation to weld the
parts together.

Overlap welds

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Clamping
force clamping
Step -1 Step -3
force

Step -4
Step -2

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• Frequently competes with flash or upset
welding when one of the work pieces to be
joined has axial symmetry.
• Used in automotive industry to manufacture
gears, engine valves, and shock absorbers.
• Used to join jet engine compressor parts.

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 Applications

Friction Welded Joint

Friction Welded Automotive Halfshaft

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Dissimilar Metals – Friction Welded

Aluminum to Steel Friction Weld

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• 21. Friction Welding of Solid part to
• 22. Friction Welding Piston Rods for the Construction Industry
• 23. Friction welding copper to aluminium electri

• 12.Friction Stir Welding - Process animation

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