Friction Welders
There are three styles of standard Gatwick friction welders. Our original, the Compact range, has been developed from our very roots and is used extensively throughout industries in various sizes from 2.5 tons maximum forge force to 50 ton maximum forge force.
The Modular range was evolved from the Compact Range adding special features as requested by our customers and by our research team. This range performs from 5 tons up to a maximum 250 tons forge force.
The Modular NC range is our latest series that has revolutionised our methods of friction welding. The machinery out performs existing units in terms of flexibility of process, working to tighter specifications and by being able to weld a greater range of material combinations. This series of machines perform in the range from 2.5 tons to in excess of 250 tons.
The entire series of friction welders takes advantage of all the latest design innovations, producing a machine that gives perfect welds under closed loop control conditions. Gatwick machines are suitable for a wide range of components. Gatwick Fusion can offer advice as to the suitability of your application and the correct machine to use.
Our standard NC range consists of:
NC4000 View Datasheet
NC7000 View Video
NC10,000
NC20,000
NC60,000
NC80,000
NC120,000
NC175,000 View Datasheet
NC250,000
- Specifications
- Software
- Applications
- Process
- Industries
| Friction Welding Machine – NC4000 | |
|---|---|
| MAX. WELD AREA |
180mm2 (Copper/Aluminium) 78mm2 (Alloy Steel) |
| TOTAL CONNECTED POWER |
37kW |
| SPINDLE SPEED |
1000-6000rpm (1rpm variable) |
| MAXIMUM BAR CAPACITY |
15mm Diameter |
| MINIMUM BAR CAPACITY |
4mm Diameter |
| MAXIMUM DEPTH SPINDLE BACKSTOP |
250mm |
| TRAVEL HEAD STROKE |
200mm |
| MAXIMUM HYDRAULIC PRESSURE |
140 bar |
| MAXIMUM FORCE |
3,000 Kg |
| TYPICAL PRODUCTION RATE |
300 / hour (Manual) 400 / hour (Automatic) |
| MAXIMUM WELD DIAMETER |
15mm Diameter (Cu/Al) 10mm Diameter (Alloy Steel) |
| Friction Welding Machine – NC7000 | |
|---|---|
| MAX. WELD AREA |
490mm2 (Copper/Aluminium) 200 mm2 (Alloy Steel) |
| TOTAL CONNECTED POWER |
45kW |
| SPINDLE SPEED |
1000-6000rpm (1rpm variable) |
| MAXIMUM BAR CAPACITY |
25mm Diameter |
| MINIMUM BAR CAPACITY |
4mm Diameter |
| MAXIMIUM DEPTH SPINDLE BACKSTOP |
250mm |
| TRAVEL HEAD STROKE |
300mm |
| MAXIMUM HYDRAULIC PRESSURE |
140 bar |
| MAXIMUM FORCE |
7,000 Kg |
| TYPICAL PRODUCTION RATE |
280 / hour (Manual) 360 / hour (Automatic) |
| MAXIMUM WELD DIAMETER |
25mm Diameter (Cu/Al) 16mm Diameter (Alloy Steel) |
| Friction Welding Machine – NC10,000 | |
|---|---|
| MAX. WELD AREA |
700mm2 (Copper/Aluminium) 315mm2 (Alloy Steel) |
| TOTAL CONNECTED POWER |
55kW |
| SPINDLE SPEED |
100-4000rpm (1rpm variable) |
| MAXIMUM BAR CAPACITY |
30mm Diameter |
| MINIMUM BAR CAPACITY |
4mm Diameter |
| MAXIMIUM DEPTH SPINDLE BACKSTOP |
250mm |
| TRAVEL HEAD STROKE |
300mm |
| MAXIMUM HYDRAULIC PRESSURE |
140 bar |
| MAXIMUM FORCE |
10,000 Kg |
| TYPICAL PRODUCTION RATE |
200 / hour (Manual) 250 / hour (Automatic) |
| MAXIMUM WELD DIAMETER |
30mm Diameter (Cu/Al) 20mm Diameter (Alloy Steel) |
| Friction Welding Machine – NC60,000 | |
|---|---|
| MAX. WELD AREA |
3500mm2 (Alloy Steel) |
| TOTAL CONNECTED POWER |
60kW |
| SPINDLE SPEED |
100-4000rpm (1rpm variable) |
| MAXIMUM TUBE CAPACITY |
133mm Diameter |
| MINIMUM BAR CAPACITY |
20mm Diameter |
| MAXIMIUM DEPTH SPINDLE BACKSTOP |
250mm |
| TRAVEL HEAD STROKE |
300mm |
| MAXIMUM HYDRAULIC PRESSURE |
160 bar |
| MAXIMUM FORCE |
60,000 Kg |
| TYPICAL PRODUCTION RATE |
50 / hour (Manual) 60 / hour (Automatic |
| MAXIMUM WELD DIAMETER |
55mm Diameter (Alloy Steel) |
| Friction Welding Machine – NC175,000 | |
|---|---|
| MAX. WELD AREA |
12,260mm2 (Drill Pipe Steel) |
| TOTAL CONNECTED POWER |
200kW |
| SPINDLE SPEED |
1-800rpm (1rpm variable) |
| PIPE DIAMETER RANGE |
2 3/8" - 6 5/8" (Inches) Drill Pipe API Spec D |
| MACHINE WEIGHT |
55 Tonnes |
| MAXIMIUM DEPTH SPINDLE BACKSTOP |
Within Tooling Design |
| TRAVEL HEAD STROKE |
900mm |
| MAXIMUM HYDRAULIC PRESSURE |
210 bar |
| MAXIMUM FORCE |
1,740 kN |
| TYPICAL PRODUCTION RATE |
10 - 20 Parts per Hour |
| PIPE LENGTH RANGE |
Unlimited |
GS Control Software
The Siemens controller used is an NC control type 840D NCU 571.2, with interface OP10. A Siemens servo drive motor type 1FT6 will be supplied for spindle rotation driven by Simodrive 611D speed variator.
All software for the control process is written to combine with the hardware configuration such that the system operates in complete closed loop control. The use of a unique hydraulic module allows the main force axis to be controlled in the same manner and thus making the finite control of all weld parameter achievable to incredibly high repeatable levels.
The use of this control technology gives advantages in the fine setting of parameters and limits with the added bonus that operator use is easy via special front end menus and password protection of the process.
TYPICAL APPLICATIONS:
Drill Pipe
Solid Engine Valves
Hollow Engine Valves
Driveshafts
Axles
Turbochargers
Airbags
The above examples are typical friction welding applications, however, our NC range of friction welders have the facility to stop the spindle to a known position to within 0.1 degree. This feature can allow friction welding to be a suitable process for assymetical applications. To see this in action click here to view a video.
What is Friction Welding?
- Friction welding is a solid-state process that is achieved through frictional heat.
- This heat is generated by controlled contact of two components until material reaches its plastic state, at which time plasticised material begins to form layers that intertwine with one another.
- The friction welding machine controls this contact through a series of unique parameters for rotational speed (rpm’s), axial force and time.
- Once these parameters are established, they are recorded, stored and then repeated with each cycle of the machine.
Why Friction Welding?
- No filler material, flux or shield gas Environmentally clean; no arcs, sparks, smoke or flames
- Surface impurities burn through during process
- Narrow heat affected zones
- Ability to weld dissimilar metals
- Weld strength usually as strong or stronger than the weaker material being joined
- Operators do not require manual operating skills
- Simple integration into the manufacturing area
- Easily automated for mass production
- Minimal plant requirements to install
FPE and Gatwick Fusions range of Friction Welders are suitable for the following industries:
• AEROSPACE
• AUTOMOTIVE
• CUTTING TOOLS
• ELECTRICAL
• INDUSTRIAL
• OIL AND ROCK EXPLORATION
• WHITE GOODS
