Friction welding is a solid state process most frequently used for metal and plastics joining, but which may be applied for joining ceramics to metals. One material, usually the ceramic, is held stationary, whilst the other material, frequently a soft metal such as aluminium, is rapidly rotated. The rotating metal is then brought into contact with the ceramic under load with a force being maintained for a pre-set time after rotation has ceased. The soft metal deforms, forming a characteristic flash, and keys into the ceramic surface to produce a mechanically interlocking bond.

The process has been applied to aluminium for alumina, silicon carbide, zirconia and aluminium nitride and joint sizes of up to 50mm2 have been produced.

TWI can offer the following facilities:

Joint design
Materials selection
Process selection
A large range of friction welding machines
Joint analysis by SEM, optical, EDX, mechanical testing

Further information

Knowledge summaries: Joining ceramics by friction heating and forging
FAQs: Can ceramics be friction welded to metals?; Is it possible to braze using friction based processes?; What materials are difficult to join using friction welding?
Staff papers: Techniques for bonding ceramics (Bulletin, September/October 1990) Industrial Members Only

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