Hastelloy Welding

Friction welding provides a perfect solution for welding Hastelloy to Hastelloy or other dissimilar metals – Creating high-strength, defect-free joints without melting or needing filler material. Hastelloy is a group of corrosion-resistant alloys known for their exceptional strength, resistance to high temperatures, and compatibility with corrosive environments, making them crucial in aerospace, chemical processing, and oil refining industries. The rotary friction welding process generates frictional heat between two components and subsequently forges them under pressure, ensuring a metallurgically sound bond. This technique maintains the unique properties of Hastelloy and minimizes the risk of cracking in the weld, distortion, or degradation that can occur with traditional welding methods. As industries continue to demand reliable joining methods for specialized materials like Hastelloy, friction welding is a solution that meets the stringent requirements of these applications.

Hastelloy Friction Welding

Hastelloy Weld Specification

AFW works with customers to define a Weld Procedure Specification (WPS) that sets specific tolerance parameters for each part. Equipped with advanced high-precision controllers, our welding centers monitor all critical variables throughout the weld cycle, guaranteeing product conformance – RPMs (rotations per minute), PSI (weld pressure), and total stock length loss. Controlling forge ramp and deceleration is critical in maintaining consistent and standardized welds. The operator receives immediate notification if a weld parameter is out of range to take corrective action. We record data from each weld cycle for future parameter review and analysis.

The graph displays a friction weld cycle of RPMs, PSI, and stock displacement.

hastelloy Friction Weld Graph

Hastelloy Weld Bend Test

Friction welding bend tests are common to assess mechanical integrity and bonding strength. This testing method involves subjecting a friction-welded specimen to bending forces, which simulate real-world conditions and evaluate the weld’s resistance to deformation. A predetermined load is applied gradually to the sample during the test to achieve the desired bend angle. The test measures parameters such as the ultimate bending moment, the yield strength, and the ductility of the weld. By performing friction welding bend tests, engineers and researchers gain valuable insights into the quality and reliability of friction-welded joints, helping to ensure the structural integrity and performance of welded components in various applications.

Weld Bend Test

Working With Hastelloy

Friction welding is a solid-state joining process that involves metals bonding through heat generation from mechanical friction. When friction welding Hastelloy, specifically Hastelloy C-276, a corrosion-resistant nickel-molybdenum-chromium alloy, several critical factors come into play. Unlike traditional arc welding methods, friction welding does not involve melting the base metal; instead, the heat input is localized at the interface, resulting in minimal distortion, a narrow heat-affected zone, and requiring minimal joint surface preparation prior to welding. The absence of melted weld metal and the lower heat input reduce the risk of undesirable metallurgical changes and maintain the material’s corrosion resistance. However, post-friction welding heat treatment might still be necessary to refine the microstructure and relieve residual stresses. Monitoring and controlling interpass temperatures are crucial to prevent overheating and ensure the desired mechanical properties of the friction-welded Hastelloy joint.

  • Melting Point: 2,300 - 2,470°F | 1,260 - 1,354°C
  • Thermal Conductivity: 9.8 W/m-K (watts per meter per kelvin)
  • Grades: Hastelloy Alloy B, B-2, B-3, C-4, C-22, C-22HS, C-86, C-276, C-2000, D-205, G-3, G-30, G-35, G-50, HYBRID-BC1, N, S, W, and X
Hastelloy is a registered trademark of Haynes International.
Contact American Friction Welding today for more information or to request a quote!