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Friction Welding Machines

Friction Welding Machines
Friction Welding Machines Friction Welding Machines Friction Welding Machines Friction Welding Machines Friction Welding Machines 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 250 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 consultancyy 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.

NC2800VNEW vertical machine ideal for small components or demo systems in Universities or institutes.
NC4000
NC7000View Video on Gatwick's YouTube channel. MP4 on Website.
NC10,000
NC20,000
NC60,000Rock Drill Pipe Friction Welding Machine.  View Video on Gatwick's YouTube Channel.
NC80,000
NC120,000
NC175,000Oil 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.

Software

Drill Pipe


Solid Engine Valves

ENGINE VALVES

Hollow Engine Valves

HOLLOW ENGINE VALVES


Driveshafts

DRIVESHAFTS


Axles

AXLES


Turbochargers

turbochargers


Airbags

turbochargers


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

FRICTION WELDING PROCESS

Gatwick® Technologies range of Friction Welders are suitable for the following industries:

• AEROSPACE
• AUTOMOTIVE
• CUTTING TOOLS
• ELECTRICAL
• INDUSTRIAL
• OIL AND ROCK EXPLORATION
• WHITE GOODS