1. Part type

Select the joint geometry.

2. Interface preparation

How are the faces prepared? Affects ramp times and initial torque.

3. Materials

Rotating component

Stationary component

Loading material data…

Custom material parameters

Enter values from your WPS, customer spec, or trial data.

Friction P min (MPa)

Friction P max (MPa)

Forge P min (MPa)

Forge P max (MPa)

Surface speed min (m/s)

Surface speed max (m/s)

Hot flow stress (MPa)

Notes (optional)

4. Recommended weld range zone

Select the preferred weld range zone based on published recommendations.

Lower third

Lower forces and speeds

Mid range

Centre of recommended window

Upper third

Higher forces and speeds

5. Material welding ranges

Auto-populated from the overlap of both materials' published ranges. Switch to Custom to override these for trial-tuning or supplier-spec work — the strategy slider above will then pick within your custom window, and all forces, speeds, and times will be recalculated.

Range values for established materials come from published friction welding reference data. Any material derived from engineering estimate is clearly tagged in the material info.

Friction force

– t

– kN

Forge force

– t

– kN

Surface speed

– m/s

–

6. Geometry

Outer diameter, D 25 mm

Inner diameter, d (tube) 0 mm

7. Pre-weld lengths and finished length

Part length 1 (mm)

Part length 2 (mm)

Weldment finished length (mm)

Part length 1 tolerance ± (mm)

Part length 2 tolerance ± (mm)

Weldment finished length tolerance ± (mm)

Burn-off is estimated from Part 1 + Part 2 − Finished length, split between the friction phase (~80%) and forge upset (~20%).

Enter your component details above, then click Generate Parameters.

Friction welding parameter sheet

Generated — · Griffiths Engineering Solutions Ltd

Part type: —

Interface: —

Weld range zone: —

Rotating material: —

Stationary material: —

OD / ID: —

Welding cross-section: —

Pre-weld / finished length: —

Calibration confidence: —

Recommended welding parameters

Block A below is the machine setpoint sheet — these are the values generally used by a friction welder to create a successful weldment. Block B contains derived process insight (forces in kN, surface speeds, torque, energy, predicted cycle) for sizing and sanity checks but is not entered into the machine.

High confidence — parameters within typical engineering experience for this size range.

Block A — Machine setpoints

Component pre-weld length tolerances

Min pre-weld length (Part 1 + Part 2 − tol)

—mm

Max pre-weld length (Part 1 + Part 2 + tol)

—mm

Weldment length tolerances

Min post-weld length (Finished − tol)

—mm

Max post-weld length (Finished + tol)

—mm

Burn-off

Recommended burn-off minimum (GES guidance)

—mm

Calculated burn-off

—mm

Burn-off rate (est.)

—mm/s

Forces

1st friction force (P1)

—kN

2nd friction force (P2)

—kN

Forge force (P3)

—kN

1st friction force (P1)

—t

2nd friction force (P2)

—t

Forge force (P3)

—t

Times

The ramp time is included in the friction time — i.e. friction time is measured from force ramp start to end of phase.

1st friction — ramp

—s

1st friction — total

—s

2nd friction — ramp

—s

2nd friction — total (estimated)

—s

Forge delay

—s

Forge duration

—s

Speeds

1st friction speed (N1)

—rpm

2nd friction speed (N2)

—rpm

Monitors

Watchdog thresholds — the machine flags or aborts if the actual process drifts outside these bounds.

2nd friction monitor force

90% of P2

—kN

—t

2nd friction min time (t₂ − 3 s)

—s

2nd friction max time (t₂ + 3 s)

—s

2nd friction monitor speed (90% of N2)

—rpm

Forge monitor force

90% of P3

—kN

—t

Forge max ramp time (forge ramp + 1 s)

—s

Deceleration max time (decel + 1 s)

—s

Block B — Process insight & machine demand

Derived values — useful for sizing the machine and sanity-checking the procedure, but not entered into the welder.

Contact area

—mm²

Surface speeds & machine demand

1st friction surface speed

—m/s

2nd friction surface speed

—m/s

Engineering detail ges

Diagnostic numbers used for drive sizing and weld-physics sanity-checking. Hidden from operators by default.

Peak spindle power

—kW

—

Average spindle power

—kW

—

Peak friction torque (1F)

—N·m

Heat input rate (1F)

—kW

Energy delivered (1F)

—kJ

Predicted T at end of 1F

—°C

Time to visible glow

—

Machine response times

Mechanical response times — the welder runs these as fast as the hydraulics and spindle inertia allow. Shown for sizing / sanity-check; not programmed.

Forge ramp (estimated)

—s

Deceleration time (estimated)

—s

Length budget & totals

Forge upset

—mm

Total length loss

—mm

Total friction time

—s

Total cycle time (approx.)

—s

Predicted weld cycle

Schematic of force, spindle speed, and displacement against time — based on the generated parameters above. Idealised; real-process traces will be noisier.

Surface speed within typical range.

WPS metadata

Burn-off mode: Constant (Position / Constant / Timed)

Welding mode: Force (Force / Burn-off rate)

Burn-off rate: N/A mm/s — only when welding mode = Burn-off rate

Brake delay: _____ s

Pre-weld heat treatment: _____________________________________

Post-weld heat treatment: _____________________________________

Calculated by: ___________________________ Date: ___________

Examined by: ___________________________ Date: ___________

Signature: _____________________________

Disclaimer: All calculated values are guidance only and intended as a starting point for trials and procedure development. Griffiths Engineering Solutions Ltd accepts no responsibility for outcomes resulting from their use. It is recommended that all welds are qualified to a recognised standard (e.g. ISO 15620, AWS C6.1) before production.

▶ Show process parameter detail

Values the calculator chose, with the underlying pressures and friction coefficient used for torque/power.

Parameter	Value	Source
P1 pressure	— MPa	30% of P2 (light pre-heat, prevents spin-ups)
P2 pressure	— MPa	From material range × operating point
P3 (forge) pressure	— MPa	From forge range × op point; enforced ≥ 1.15 × P2
N1 — 1st friction speed	— rpm	1.4 × N2 (higher speed for cleaning action)
N2 — 2nd friction speed	— rpm	From target surface speed at OD (P2 stage)
Target surface speed (P2)	— m/s	From material range × operating point
μ for 1F peak (cold start)	0.45	Dry steel-on-steel asperity contact; drives peak motor demand
μ for 2F average (steady state)	0.25	Plasticised hot interface; representative of bulk weld cycle
Glow temperature target	550 °C	Dull red, visible in shop lighting
Burn-off split (friction / forge)	80% / 20%	Typical industry default

Weld cycle phases

1 — Initial / dry friction

High μ, asperity contact, rapid temperature rise. Torque peaks early.

2 — Unsteady / transition

Plasticised layer forms, μ drops, torque falls. Flash begins to extrude.

3 — Steady-state friction

Quasi-stable plastic zone, near-constant torque, controlled axial shortening.

4 — Forge / upset

Rotation stops, P3 applied. Consolidates joint, expels oxides into flash.

Parameter Generator

1. Part type

2. Interface preparation

3. Materials

Custom material parameters

4. Recommended weld range zone

5. Material welding ranges Published Custom

6. Geometry

7. Pre-weld lengths and finished length

Friction welding parameter sheet

Recommended welding parameters Print / save as PDF

Component pre-weld length tolerances

Weldment length tolerances

Burn-off

Forces

Times

Speeds

Monitors

Contact area

Surface speeds & machine demand

Engineering detail ges

Machine response times

Length budget & totals

Predicted weld cycle

Weld cycle phases

5. Material welding ranges

Recommended welding parameters