Requires Job Setup
Friction Welding is a machine based process. The machines are large and configured for universal use in our plant. This means that each job requires a setup stage that requires a technician and supervisor. The size of equipment means that components are moved slowly using overhead material handling lifts. Workholding fixtures assigned to the job must be located and installed into the machine. These steps are followed by the calibration steps to make sure parts will be made to specifications on the control plan.
Some parts are simple in their configuration, and can be run using standard clamps in the chuck jaws and tailstock of the machines.
Job setups in our plant run from $500-$1000 depending on the machine size and part complexity.
Friction Weld Flash
Might Cause Additional Work
The friction welding process produces a side effect of out-flowing upset material from the weld zone. This will form a ring around the weld, and sometimes that “Flash” ring must be removed before subsequent procedures are applied to the weldment. Charges for this can sometimes cost as much as making the weld itself.
Tooling and Weld Prove-Out
Each new part inquiry is analyzed and assessed for workholding needs. If the part is complex, then workholding fixtures must be made to adapt the general purpose friction welding machines to uniquely shaped sub-components that are to be joined into weldments.
We also compare the material chemistry and part dimensions to our catalog of weld parameters. When a new material chemistry and dimensional configuration is encountered, then a weld prove-out is required to establish a satisfactory weld parameter for that specific part.
Tooling charges at AFW can run from $1,000 to $5,000 and up from there depending on complexity. We do operate our own tool room with toolmakers on staff to contain this expense and start-up lead-times.
Weld Prove-Out can be as little as $800-$2000 for an easy to handle material chemistry. A full weld development process is sometimes called for with complex pieces using unusual material chemistry. We have seen specialized weld development charges in the range of $20,000 on occasion.
What Will Friction Welding Cost You?
Quantity of Job Lot
Divide Fixed Costs by Number of Pieces on Order
The fixed cost of setup are divided by the number of pieces in an order. Job lot minimum charges are derived from the expense necessary to cover these.
Operation Cycle Time
After figuring the fixed cost per part, cycle time of the process is calculated. Machine and labor rates are multiplied by the cycle time and added to the fixed cost per piece.
The actual dollars involved in this stage of estimating vary widely based on machine size choice, complexity of part, packaging requirements, and test requirements for the part quality.
For more information on price,
See Our Blog Article on Bi-Metal and CNC Machined Components