Friction Welding is a preferred joining method of multiple industrial manufacturers for a variety of compelling reasons:
One of the fascinating reasons to specify Friction Welding is the ability to create a finished composite part using dissimilar materials.
Friction Welding comes into the pictures when designers address the cost of those expensive materials. What if the resistant material is only needed at a specific point of exposure? Can the remainder of a shaft be made from carbon steel? If so, the expensive alloy can be joined with Friction Welding to create a composite part.
Certain applications expose machine components to harsh conditions involving chemicals, acids, or fuels. Others handle food or pharmaceuticals. In all cases, cleanliness is crucial. Designers turn to stainless steel and other high-nickel alloys to address this exposure. Industry examples can be found in wash-down motor shafts, marine prop-shafts, and various pumps.
In the utility industry, the electric current must be handled as it travels across different metals. Consider busses and fuses that move the current from an aluminum surface to an opposing contact point. The ability to join aluminum to copper in a way that prevents arcing within the joint becomes essential. Friction Welding can produce such a joint.
The ability to join two different types of metal at a seam opens all kinds of flexibility for designers. Check this material list for example combinations.