Linear Friction Welding

The Linear Friction Welding Process

Up until now, friction welding could only be used on joints that had at least one round part but Thompson’s innovation means the process can be used on almost any shape. The advantages of this solid state process also mean that similar and dissimilar materials such as aluminium and copper can be completely joined, no filler material is needed and the parts do not melt so better parent material properties can be achieved.

Linear friction welding works on the basic principles of rubbing 2 pieces of material together until the surface gets hot enough to become plastic and join together. This principle has been used in rotary friction welding by Thompson for over 50 years where one part is spun against another, heat is produced and the parts are forced together. The basic parameters mean that oscillation replaces rotation but the remaining characteristics are very similar to rotary welding.

Whatever the size of the part, the weld times are similar in speed because the linear process, unlike the rotary method, ensures that friction occurs throughout the weld surface The largest linear friction weld undertaken by Thompson to date had a weld time of around 4 seconds.

The flash of excess material formed during the weld will expel from the joint line in an even plane and show the number of oscillations that have occurred during the weld. This can be removed by hand or automatically on the machine.

Check out http://www.linearfrictionwelding.com/ for more information

LINEAR FRICTION WELDING SOLUTION FOR JOINING AERO PARTS

Thompson will showcase its linear friction welding solution for producing a range of titanium aero components at a fraction of the cost of other traditional manufacturing methods on stand B10, Hall 4, at theFarnborough International Air Show.

The award-winning machine manufacturer says the linear process can be used to make tailored blanks, which eliminate the need for vast amounts of raw material usually associated with machining components from solid billets.

Thompson says these pre-formed components offer typical savings of 70 per cent and adds that its work with some of the world's top aircraft makers has already identified a number of parts that show potential multi-million dollar savings in material.

Its new E100 machine is specially designed to use the linear friction welding process to join one or more parts together to create larger structures and prismatic shapes. The method produces a solid phase bond with near parent metal properties.

Tailored blanks offer an attractive alternative to machining as many aircraft components have complex shapes such as stringers, flanges and webs added to their basic construction, explained Nick Edge, Thompson's global sales manager.

"In order to arrive at the net finished shape, a significant amount of raw material has to be removed during the machining process and this results in high buy-to-fly ratios of 10:1. Using the linear method means buy-to-fly ratios can be as low as 2:1," he added.

While other technologies such as laser welding and metal deposition remain in the very early stages of development, linear friction welding is an established process that has been successfully used for more than two decades by jet engine makers to produce safety-critical components such as blisks, said Nick.

"The continuing growth in raw material prices and the wider use of difficult-to-machine materials such as titanium alloys means the application of linear friction welding can make a major contribution to lowering production costs."

Thompson's E100 is the first in a series of linear friction welding machines for aerospace applications and complements the Halesowen-based company's range of rotary friction welding machines which are used to produce parts for the automotive, construction machine and mineral exploration industries.

Linear friction welding involves rubbing two pieces of material together while applying a load to produce frictional heat. It can be used to join similar/dissimilar materials in almost any shape from rings and blades to fans and square metal contactors.

Further information on Thompson's E100 linear friction welding machine can be viewed online atwww.linearfrictionwelding.com or emailsales@linearfrictionwelding.com.

Thompson will share its stand at Farnborough with sister company, KUKA Automation + Robotics, who will be demonstrating its latest robotic end effector solutions for aerospace applications.

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PRIME MINISTER IS FULL OF PRAISE FOR MIDLANDS ENGINEERING FIRM

Prime Minister Gordon Brown has praised a Midlands engineering company for putting “British manufacturing on the map” during a visit to its Halesowen headquarters.

He congratulated Thompson, the award-winning manufacturer of friction welding machines, on its export sales achievements and commended its innovation and investment in apprenticeships.

The Prime Minister, who was accompanied by Business Secretary Lord Mandelson and Halesowen MP Sylvia Heal, was shown one of the company’s latest friction welding machines, which is being built for a Chinese automotive axle manufacturer.

Mr Brown also took questions from Thompson employees on a range of issues as he visited the region ahead of the final leaders’ debate at Birmingham University.

“I want to congratulate you on coming through a difficult economic period, for the great technological skills you are developing, for putting British manufacturing on the map in every continent of the world and for hiring apprentices even in difficult times,” he told staff.

The Labour leader also praised Thompson for achieving a Queen’s Award for Enterprise, which recognised the company’s remarkable export sales record in the last three years.

Alan Shilton, Thompson’s managing director, said he was delighted to welcome the Prime Minister to the factory and provide an insight into how a Black Country business was flying the flag for British industry.

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