Friction Welding Machines
The Gatwick NC range of Friction Welding Machines have revolutionised the way the friction welding process takes place. Rather than just an evolution from the original Gatwick compact range of friction welders developed in the 60's which operated on an old clutch and brake system, Gatwick embraced all the latest electrical and mechanical technologies to develop the most advanced Friction Welding Machines in the world using fully closed loop CNC technology. The machines are ideal for a whole range of industrial applications including oil drill pipe welding and rock drill pipe welding.
Cutting Edge Modular Design
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 600 tons.
CNC Precision and Control
The entire series of friction welding machines takes advantage of all the latest design innovations, producing a machine that gives perfect welds under CNC fully closed loop control conditions. Gatwick machines are suitable for a wide range of components. Gatwick Technologies can offer free consultancy as to the suitability of your application and the correct machine to use. The fully closed loop CNC control also provides exceptional real-time or recorded true data acquisition.
| NC2800V | NEW vertical machine ideal for small components or demo systems in Universities or institutes. |
| NC4000 | |
| NC7000 | View Video on Gatwick's YouTube channel. MP4 on Website. |
| NC10,000 | |
| NC20,000 | |
| NC60,000 | Rock Drill Pipe Friction Welding Machine. View Video on Gatwick's YouTube Channel. |
| NC80,000 | |
| NC120,000 | |
| NC175,000 | Oil Drill Pipe Friction Welding Machine. View Video on Gatwick's YouTube channel. |
| NC250,000 |
- Specifications
- Software
- Applications
- Process
- Industries
| Gatwick Friction Welding Machine | NC2800V (vertical) |
|---|---|
| MAX. WELD AREA | 180mm2 (Copper/Aluminium) 78mm2 (Alloy Steel) |
| TOTAL CONNECTED POWER | 37kW |
| SPINDLE SPEED | 1000-6000rpm (1rpm variable) |
| MAXIMUM BAR CAPACITY | 10mm Diameter |
| MINIMUM BAR CAPACITY | 4mm Diameter |
| MAXIMUM DEPTH SPINDLE BACKSTOP | 250mm |
| TRAVEL HEAD STROKE | 250mm |
| MAXIMUM HYDRAULIC PRESSURE | 140 bar |
| MAXIMUM FORCE | 28 KN |
| TYPICAL PRODUCTION RATE | 300 / hour (Manual) 400 / hour (Automatic) |
| MAXIMUM WELD DIAMETER | 15mm Diameter (Cu/Al) 10mm Diameter (Alloy Steel) |
| Gatwick 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 | 40 KN |
| TYPICAL PRODUCTION RATE | 300 / hour (Manual) 400 / hour (Automatic) |
| MAXIMUM WELD DIAMETER | 15mm Diameter (Cu/Al) 10mm Diameter (Alloy Steel) |
| Gatwick 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 |
| MAXIMUM DEPTH SPINDLE BACKSTOP | 250mm |
| TRAVEL HEAD STROKE | 300mm |
| MAXIMUM HYDRAULIC PRESSURE | 140 bar |
| MAXIMUM FORCE | 70 KN |
| TYPICAL PRODUCTION RATE | 280 / hour (Manual) 360 / hour (Automatic) |
| MAXIMUM WELD DIAMETER | 25mm Diameter (Cu/Al) 16mm Diameter (Alloy Steel) |
| Gatwick Friction Welding Machine | NC10000 |
|---|---|
| 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 |
| MAXIMUM DEPTH SPINDLE BACKSTOP | 250mm |
| TRAVEL HEAD STROKE | 300mm |
| MAXIMUM HYDRAULIC PRESSURE | 140 bar |
| MAXIMUM FORCE | 100 KN |
| TYPICAL PRODUCTION RATE | 200 / hour (Manual) 250 / hour (Automatic) |
| MAXIMUM WELD DIAMETER | 30mm Diameter (Cu/Al) 20mm Diameter (Alloy Steel) |
| Gatwick Friction Welding Machine | NC60000 |
|---|---|
| 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 |
| MAXIMUM DEPTH SPINDLE BACKSTOP | 250mm |
| TRAVEL HEAD STROKE | 300mm |
| MAXIMUM HYDRAULIC PRESSURE | 160 bar |
| MAXIMUM FORCE | 600 KN |
| TYPICAL PRODUCTION RATE | 50 / hour (Manual) 60 / hour (Automatic |
| MAXIMUM WELD DIAMETER | 55mm Diameter (Alloy Steel) |
| Gatwick Friction Welding Machine | NC175000 |
|---|---|
| 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 |
| MAXIMUM 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.
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 asymmetrical applications.
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
Gatwick® Technologies range of Friction Welders are suitable for the following industries:
• AEROSPACE
• AUTOMOTIVE
• CUTTING TOOLS
• ELECTRICAL
• INDUSTRIAL
• OIL AND ROCK EXPLORATION
• WHITE GOODS
