Automatic Control System for Friction Welding Machine

Process Description

Friction welding is a type of pressure welding in which heating is achieved through friction caused by the rotation of one of the components being joined. The process occurs in the solid state due to heat generated by friction between the surfaces of the parts to be welded.

The main types of welded joints in friction welding include butt joints of rods and pipes, as well as connections of rods or pipes to flat surfaces.

System Requirements

• Ease of operation
• Safety
• Reliability

System Solution and Characteristics

The control system is built on a Mitsubishi Electric MELSEC FX3U programmable logic controller and a GOT1000 GT1655 operator panel. The controller manages the process via discrete and proportional hydraulic valves and solenoid actuators.

An intuitive graphical user interface allows operators to easily adjust machine operation modes, monitor process parameters, and receive diagnostic notifications.

Results and Benefits

• High productivity: depending on material properties and part dimensions,
  the welding cycle lasts from a few seconds to one minute.
• Energy efficiency: energy consumption is 5–10 times lower than that of butt resistance welding.
• Excellent joint quality: the strength of the weld and adjacent area
  is comparable to that of the base material.
• Versatility: the process enables welding of both similar and dissimilar metals,
  such as steel to aluminum or copper, and aluminum to copper or titanium.