Since the advent of the friction welding process in 1956 and its early application, it has been followed by comprehensive investigations and considerable research effort has been made in U.S.S.R. Japan. U.K. U.S.A. and Europe to find out the most appropriate friction welding process conditions for welding certain pairs of different sizes and configurations. Despite this considerable work, the understanding of the basic mechanism involved in friction welding did not keep pace with the rapid increase in industrial application of the process. This was Probably due to partly relative insensitivity of the weld quality to variation in process control parameters; speed, pressure and burn off and partly to the fact that complex mechanisms are involved in the friction generation of heat and the consolidation of the weld. In this research, it has been deliberated to identify basic or minimum requirements in connection with the production of sound friction welds of mild steel work Pieces. Minimum energy input per unit area of the weld has been calculated and process parameters are recommended for production of sound welds in the mild steel work pieces of round and tabular cross-sections. Mechanical tests have been carried out on test samples welded by friction welding. Results have been discussed.

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