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process ::
cold forming ::
automatic screw machining ::
welding ::
secondary operations
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What is Inertia Welding?
Inertia Welding is a welding process in which the energy required to make
the weld is supplied primarily by stored rotational kinetic energy of the
welding machine.
In Inertia Welding, one of the work pieces is connected to a flywheel and the
other is restrained from rotating. The flywheel is accelerated to a predetermined
rotational speed, storing the required energy. The drive motor is disengaged and
the work pieces are forced together by the friction welding force. This causes
the facing surfaces to rub together under pressure. The kinetic energy stored in
the rotating flywheel is dissipated as heat through friction at the weld interface
thus welding the two surfaces together as the flywheel speed decreases ending with
the weld stopping the flywheel.
When should the Inertia Weld Process be considered:
When a part shape or size does not lend it self to one
manufacturing process. Two separate processes can be used for the different features of the part and then joined by the Inertia Weld process
When two different materials are needed in one part.
Example one part needing corrosion resistance and another area needing a hardenable steel
Where the present joining method is not satisfactory
The Value of Inertia Welding
The process is at least twice - and up to 100 times - as fast as other welding techniques.
Since there is no melting, no solidification defects occur, e.g. gas porosity, segregation or
slag inclusions. Joint preparation isn't critical... machined, saw cut, and even sheared surfaces are weldable.
Resulting joints are of forged quality, with a 100% butt joint weld through the contact area.
No consumables required - no flux, filler, or shielding gases required.
The machine - controlled process eliminates human error, and weld quality is independent of operator skill or attitude.
No weld spatter and few sparks produced.
Summary of Benefits:
Increased Design Options
Parts made of Dissimilar Metals
Odd Shaped Parts produced at Lower Cost
Parts Welded with no Visible Seam
Joints with Total Contact Area Welded
Metallurgically Superior Welds
Easily Automated Weld Process
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