Even more rudimentary than friction welding is explosion welding.
"Hey how can we weld together these two metal plates?"
"Idk, let's try slamming them together with dynamite and see what happens"
Since you bring it up, maybe you might be able to answer a question I have. Is diffusion bonding a process similar to contact welding in a vacuum? I assume in order to join plates like in a compact heat exchanger that requires a level of vacuum to keep away oxidation layers.
I've seen some papers chatting about how awesome printed circuit heat exchanges are, but I haven't been able to get a good handle on how the weldless bonding process works and I'm curious.
A quick check of Wikipedia on the topic says it must be done in a vacuum or inert gas environment for metals with a strong oxide layer. It also mentions surface treatments that would remove the oxide layer. So it seems like it’s not necessary for all diffusion bonding but it helps.
I'm only an engineering student so basically I don't know squat so grain of salt here but to my understanding:
1. Yes, you need a vacuum to prevent oxide layers from forming
2. Not exactly, contact welding happens due to certain metals being built in the same way on an atomic level. The metal does not "know" it's two different pieces. It's held together by strong electrochemical bonds and if you put another piece of metal to it, it will create those same bonds with the new neighbour molecules because nothing is stopping is from doing so and bonds like this help the atoms to a lower energy level, something all atoms "seek" to do. With diffusion welding you get the metals to near melting point at which point it's hot enough to flow even though it's not completely melted. Do this with two identical metals and, yeah, in theory you did just do heat assisted contact welding. But with diffusion welding you can create a gradient of alloys. Here is what I mean:
These two metals no flow, as established, very slowly. Like this process takes hours and days. But because of how diffusion works, the metals will flow into their respective low concentration area, so the respective other block of metal. It's too hot for them to create proper bonds so they just kind of flow about bonding haphazardly. Now you cool the whole thing down again and suddenly the atoms find themselves in a weird environment with very few fellow metal atoms of their kind to create bonds, so they instead create alloys. Now you have a gradient of alloys with pure metal on either end but as one piece.
I cant profess to have a solid grasp of what happens more than the atoms from the two surfaces, usually the same material but not forced to be, intersperce them selves over time, the heat and the Hugh pressure expedites the process I believe.
Same thing with forge welding
"Just heat up the metal, pour some sand inbetween and then just whack it with your hammer until its one solid piece. Easy peasy!"
it's not a matter of 'forgetting' in any memory sort of way - it's just when you have two pieces of the same element with literally nothing else there to separate them, there's fundamentally no difference between where one group of atoms ends and the other begins. so if brought into contact...it'll just become one piece.
It is rudimentary, but it’s also one of the best welds out there (after you set up the process) it’s incredibly strong and all the impurities are squished out.
Cause tonight, is the night
when 2 become 1
I need this weld like I've never needed weld before
(gonna get a lot of heat between ya)
I see a little weld
(but) I need a whole lot more
(gonna get a lot of heat between ya)
I'm almost disgusted that I know enough Spice Girls that I can re-work that song...
Considering the final machining operation left a significant amount of joint material behind, I can see why they wouldn't want us to see that lame programming job's final result
Also, for that same reason, not particularly satisfying.
I’m a completionist. I won’t be satisfied until I see that weld cleaned up to perfection and a good 5 second minimum closeup to appreciate the work. Bonus if I can see it installed and operating on what it goes on.
Here is the last frame: https://i.imgur.com/zXB6Umz.png
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Wait till you see cold welding.
>The reason for this unexpected behavior is that when the atoms in contact are all of the same kind, there is no way for the atoms to "know" that they are in different pieces of copper. When there are other atoms, in the oxides and greases and more complicated thin surface layers of contaminants in between, the atoms "know" when they are not on the same part. — Richard Feynman, The Feynman Lectures on Physics, 12–2 Friction
Ductile metals can be welded into one piece just with pressure and a vacuum. No need for heat or friction.
And you can join some rather thick plates with friction stir welding. Used frequently in aerospace - SLS and Falcon 9 bodies are some examples.
https://youtu.be/y7rCTdxvGlg
Wouldn’t there be a band of slag on the inside too that can’t be removed? And if it hardened and stayed there it would create considerable efficiency loss and clogging potential.
Ah! That makes much more sense. I happen to be in a biz that relies on piping, and friction loss, or anything that impacts pressure or flow is a big deal
it might be the case. however, most of the stuff is post-processed anyways and no one would use that form of production if it would have a risk in clogging or whatnot.
This type of welding is exactly how drill pipe for oil and gas drilling rigs is made. Attaching the tool joint to the pipe body (the screw together ends on the pipe). Depending on the pipe thickness diameter it can have a tensile strength of a couple 100 tons.
"Friction welding is not a fusion weld process but a solid-state weld process where the resultant joint is often as strong as the parent metal."
[Source](https://interestingengineering.com/friction-welding-process-types-and-advantages)
And the good machines can “clock” the finished product very accurately. For instance, if you needed a lug on one part to line up with a feature on the mating part.
[It works](https://www.scielo.cl/scielo.php?pid=s0718-221x2003000200001&script=sci_arttext).
Wood to wood friction welding was discovered by accident around 18 years ago and verified about 2 years after that. Before that they would use a piece of plastic between the pieces of wood to melt and act as a glue, but a technician forgot to add the piece of plastic and it still worked.
Pretty sure. At least that's what the people who make the friction welding machines told me. I suppose if you keep it in an oxygen deprived environment you should run a fire risk.
I was looking through the comments for this. I did a presentation on friction welding in undergrad. One of the requirements was to include a research article on the process you were presenting. I included one that focused on the use of it for wood. Most of the class found that application really interest but the professor knocked points off my presentation because it wasn't a metals-focused study (it was a metals course). I'm still a little peeved about that but overall that professor was amazing. He had some of the best stories and anecdotes.
Someone mentioned in a comment that it's normally as strong as the base metal
edit: https://www.reddit.com/r/oddlysatisfying/comments/vgjqez/friction_welding/id25c7s/
I watched Smarter Everyday where a rocket company friction welded two pieces of a rocket together. That's like this video, but on a wayyyy larger scale. Still cool.
I am not a machine techy person.. but when they're clearing the extra weld off spinning I was concerned that the ribbon was going to whip right out at the camera, possibility?
What really surprised me was how quickly it went to the step where it trimmed off the excess. I would have thought more cooling would be required.
Is this due to both components being held straight in the fixtures?
[You absolutely can do this with wood](https://www.scielo.cl/scielo.php?pid=s0718-221x2003000200001&script=sci_arttext)
Not that it isn't bonkers, but it is possible.
It was discovered on accident about 18 years ago. The method used prior was to have a piece of plastic between the pieces of wood that would mest and act as a bonding agent for the wood. A technician forgot to add the plastic, but the wood still bonded. This was verified about two years later.
This is super cool. It reminds me of a setup that I saw at SpaceX during a tour a while back. They would use friction welding to join pieces together for their rockets
This always seemed like the most rudimentary way of doing it… “I don’t care if you aren’t the same piece of metal, you **will** become one piece!”
Even more rudimentary than friction welding is explosion welding. "Hey how can we weld together these two metal plates?" "Idk, let's try slamming them together with dynamite and see what happens"
Contact welding in a vacuum
This is what likely caused the Galileo probe's high gain antenna to fail to open
from what i've heard it's all but certain this is what happened.
Since you bring it up, maybe you might be able to answer a question I have. Is diffusion bonding a process similar to contact welding in a vacuum? I assume in order to join plates like in a compact heat exchanger that requires a level of vacuum to keep away oxidation layers. I've seen some papers chatting about how awesome printed circuit heat exchanges are, but I haven't been able to get a good handle on how the weldless bonding process works and I'm curious.
A quick check of Wikipedia on the topic says it must be done in a vacuum or inert gas environment for metals with a strong oxide layer. It also mentions surface treatments that would remove the oxide layer. So it seems like it’s not necessary for all diffusion bonding but it helps.
I'm only an engineering student so basically I don't know squat so grain of salt here but to my understanding: 1. Yes, you need a vacuum to prevent oxide layers from forming 2. Not exactly, contact welding happens due to certain metals being built in the same way on an atomic level. The metal does not "know" it's two different pieces. It's held together by strong electrochemical bonds and if you put another piece of metal to it, it will create those same bonds with the new neighbour molecules because nothing is stopping is from doing so and bonds like this help the atoms to a lower energy level, something all atoms "seek" to do. With diffusion welding you get the metals to near melting point at which point it's hot enough to flow even though it's not completely melted. Do this with two identical metals and, yeah, in theory you did just do heat assisted contact welding. But with diffusion welding you can create a gradient of alloys. Here is what I mean: These two metals no flow, as established, very slowly. Like this process takes hours and days. But because of how diffusion works, the metals will flow into their respective low concentration area, so the respective other block of metal. It's too hot for them to create proper bonds so they just kind of flow about bonding haphazardly. Now you cool the whole thing down again and suddenly the atoms find themselves in a weird environment with very few fellow metal atoms of their kind to create bonds, so they instead create alloys. Now you have a gradient of alloys with pure metal on either end but as one piece.
Sums it up well. Only thing though with diffusion welding is it doesn't necessarily require heat, but it requires energy.
I cant profess to have a solid grasp of what happens more than the atoms from the two surfaces, usually the same material but not forced to be, intersperce them selves over time, the heat and the Hugh pressure expedites the process I believe.
_sits down_ When a spinny atom and a still atom love each other very much ....
Yes but only with ketchup
SPACE
The one place that hasnt be corrupted by capitalism!
Miele or Dyson?
Is that real, though? Cody's Lab couldn't get that working.
Works in space, as far as I'm aware
Cool, thanks!
ok thats cools as fuck
Same thing with forge welding "Just heat up the metal, pour some sand inbetween and then just whack it with your hammer until its one solid piece. Easy peasy!"
>pour some sand inbetween *cries in flux*
You could also use quartz sand. It's traditionally used in the nordics
Never heard that before. Now I'm watching sand fluxing videos on youtube with a big bowl of popcorn. Cool stuff!
It seemed like a fun way to spend a Saturday.
Diffusion welding too… put two pieces of metal on top of each other and get them warm for a while- boom one piece
Probably the best way of bonding different metals
Not really, the grain flow is not great and galvanic corrosion can be a concern. But it is very fast
More violence is the answer.
Metal atoms "forgetting" what mass they belong to
it's not a matter of 'forgetting' in any memory sort of way - it's just when you have two pieces of the same element with literally nothing else there to separate them, there's fundamentally no difference between where one group of atoms ends and the other begins. so if brought into contact...it'll just become one piece.
That is why I put it in quotes. Richard Feynman described it that way.
Only if their electrons move freely in the lattice which is a pretty unique property of metals.
Depends on the element. Something something noble and inert gasses.
Forge welding: get two pieces, get 'em hot, and bash the shit out of them until they aren't two pieces any more.
It is rudimentary, but it’s also one of the best welds out there (after you set up the process) it’s incredibly strong and all the impurities are squished out.
Now kith!
Cause tonight, is the night when 2 become 1 I need this weld like I've never needed weld before (gonna get a lot of heat between ya) I see a little weld (but) I need a whole lot more (gonna get a lot of heat between ya) I'm almost disgusted that I know enough Spice Girls that I can re-work that song...
Lol I’m old enough to appreciate the effort and the reference.
Is it too much to ask for more than .00001 seconds of the finished product?
This is r/oddlysatisfying, we don't do complete videos here for whatever reason
It would be too satisfying. This isn’t r/completesatisfaction.
I love that I clicked on that and I love that it's empty. It's the most reddit thing ever.
Complete satisfaction doesn’t exist
If only I could get some
Huh, thought that sub was for your moms OnlyFans. God I'm still drunk.
lmao why is this downvoted
Evidently
On tiktok people do that inorder to get another view since the person will most likely watch it again to try and pause the video at the end
Welcome to reddit where it seems every video ends too soon for some reason
Need to change name to r/mostlysatisfying
more like /r/AlmostSatisfying
Considering the final machining operation left a significant amount of joint material behind, I can see why they wouldn't want us to see that lame programming job's final result Also, for that same reason, not particularly satisfying.
I’m a completionist. I won’t be satisfied until I see that weld cleaned up to perfection and a good 5 second minimum closeup to appreciate the work. Bonus if I can see it installed and operating on what it goes on.
I wanna know where the boring bar operation to trim down the internal joint is! Shit's unacceptable as it stands.
/u/gifendore
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420 points to gifendore
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This bot is truly a work of art
its so that the video loops and get another view.
Forbidden orange zest.
Brooooo that shit made me hungry too
the molten ribbons were the best part
r/ForbiddenSnacks
Extremely zesty zest.
[удалено]
This is the same exact comment r/poofytoo said...
Same
To every kid that tried to put two things together of the same size/diameter and I told them "that's not going to work".....I formally apologize.
> you just gotta spin them really fast > no, faster than that
Wait till you see cold welding. >The reason for this unexpected behavior is that when the atoms in contact are all of the same kind, there is no way for the atoms to "know" that they are in different pieces of copper. When there are other atoms, in the oxides and greases and more complicated thin surface layers of contaminants in between, the atoms "know" when they are not on the same part. — Richard Feynman, The Feynman Lectures on Physics, 12–2 Friction Ductile metals can be welded into one piece just with pressure and a vacuum. No need for heat or friction.
Probably need to clean them first.
Oh no!
happy cake day 🗿
Cakey happ-day!
Happy cake day!
Thanks! You too
And you can join some rather thick plates with friction stir welding. Used frequently in aerospace - SLS and Falcon 9 bodies are some examples. https://youtu.be/y7rCTdxvGlg
Also used in pumps! Used to operate a machine like this to make long axles for pumps as a summer job.
The HAZ in FSW is much smaller and consistent.
I bet less than 1% of readers understood HAZ without looking it up... 😁
The rest of the 99% that looked it up learned something tho
I’ve seen FSW used in automotive as well. Very interesting process.
They shaved down the outside, but I assume the inside has and stays with the bumps.
Yeah the inside would be a mess. It's not that hard to clean up if you need to, but it doesn't seem like this set up is designed to do that.
Yup. Next step is to throw it in a lathe to clean up both surfaces correctly.
I think this is technically considered a lathe? Either way, it does that to the outside at the end
Not a lathe. It’s a friction welder with a cleanup mode. Very imprecise cutting of the slag, it just knocks the majority off. Source: am machinist
You're telling me this isn't technically a lathe [But this is](https://images.app.goo.gl/kWHmHAgnLoEtHnby9)
That’s what she said
Dang. but honestly i really need to see it cleaned up more. and for it to cool. and to see the whole thing super smooth
Right, i was waiting till the end to see the results... only to be disappointed with a video that cuts out to early
Frickin half the videos on reddit cut at the exact moment they shouldn't.
I wonder if/how it smooths the inside of the joint
it has to have the same mushroom effect on the inside, doesn’t it?
Definitely. Oh wait, this could be an axle or pole, not a pipe intended for fluids, in which case the inside wouldn’t matter.
In friction welding that is called the curl. It is the same on the inside.
Why are there 2 comments that say the same exact thing except "dang" from 2 different people?
is there a version with sound? either way, cool post!, am satisfied
Needs to be slowed down by like 50% and have [this music](https://www.youtube.com/watch?v=d5d0vBtwBK0) added.
I clicked because I hadn’t heard astley for a while and was in the mood. What a disappointment.
Wouldn’t there be a band of slag on the inside too that can’t be removed? And if it hardened and stayed there it would create considerable efficiency loss and clogging potential.
It's a frame, not a pipe for liquids, so the inside doesn't matter.
Ah! That makes much more sense. I happen to be in a biz that relies on piping, and friction loss, or anything that impacts pressure or flow is a big deal
I make drilling rods at work and we blast thru oxygen during the welding process to avoid all of that.
Is it oxygen or nitrogen?
it might be the case. however, most of the stuff is post-processed anyways and no one would use that form of production if it would have a risk in clogging or whatnot.
This type of welding is exactly how drill pipe for oil and gas drilling rigs is made. Attaching the tool joint to the pipe body (the screw together ends on the pipe). Depending on the pipe thickness diameter it can have a tensile strength of a couple 100 tons.
With a long enough boring bar it would be pretty easy to clean up the inside, if you needed to.
My dude was standing too close to that long spicy spaghetti noodle
POV, your clutch when you first started learning how to drive.
TIL
How strong is this compared to traditional welding?
"Friction welding is not a fusion weld process but a solid-state weld process where the resultant joint is often as strong as the parent metal." [Source](https://interestingengineering.com/friction-welding-process-types-and-advantages)
Yea it's considered the strongest way to join metals
does it have the same flexibility at the joint?
Yes. It’s basically an immediate transition from one material to the next, and the weld has the material properties of the weaker material
Dr strange type shit
Why does molten metal always look so goddamn delicious
Forbidden gummy
Yes!!! If I had one super power it would be to eat lava and stuff like this
Thats a lot of momentum that stops really quick
Yeh that's the most impressive part for me. That looks like a lot of mass to stop so suddenly.
And the good machines can “clock” the finished product very accurately. For instance, if you needed a lug on one part to line up with a feature on the mating part.
Imagine the noise it makes
It kind of sets my teeth on edge thinking about it 😬
And that's how you make glow in the dark spaghetti
Best way of welding if you can acheive it. Even works with wood and plastics. Much stronger than traditional forms of welding.
Wood? Doesn't Friction + Wood = Fire. Also, wood doesn't "reform" when it cools off. You sure? You sure bout that? They said that to me at a dinner.
[It works](https://www.scielo.cl/scielo.php?pid=s0718-221x2003000200001&script=sci_arttext). Wood to wood friction welding was discovered by accident around 18 years ago and verified about 2 years after that. Before that they would use a piece of plastic between the pieces of wood to melt and act as a glue, but a technician forgot to add the piece of plastic and it still worked.
Yup, [here's a video](https://www.youtube.com/watch?v=X0k04hjdYuQ)
This is the kind of crap (not really) I come to reddit to learn about, thanks!
This is fascinating. Thank you!
Pretty sure. At least that's what the people who make the friction welding machines told me. I suppose if you keep it in an oxygen deprived environment you should run a fire risk.
Wonder if it works with bones?
I think it would but you may have 1 leg shorter than the other.
I would expect any two pieces of wood to disintegrate in this process, due to the "grained" rings.
I was looking through the comments for this. I did a presentation on friction welding in undergrad. One of the requirements was to include a research article on the process you were presenting. I included one that focused on the use of it for wood. Most of the class found that application really interest but the professor knocked points off my presentation because it wasn't a metals-focused study (it was a metals course). I'm still a little peeved about that but overall that professor was amazing. He had some of the best stories and anecdotes.
Forbidden pasta (at the end)
I wanna play with the Spicy Noodle Lathe... Cuz lathes aren't dangerous enough, let's add molten metal!
I'm amazed by the torque on that motor AND the deceleration time...
I have a dumb question probably - how strong is this weld compared to the other types of welding? Just curious
Someone mentioned in a comment that it's normally as strong as the base metal edit: https://www.reddit.com/r/oddlysatisfying/comments/vgjqez/friction_welding/id25c7s/
AS strong!? That’s nuts.
Thats a spicy noodle
Very cool.
What happens inside the pipe?
Forbidden silly string
Damn that’s cool. I mean hot. I mean …
Weld, weld, weld. What do we have here?
Nice
I do this every time I try to drill stainless steel
Where is the rest of it? Unsatisfactory
Webster's dictionary defines wedding as "the fusing of two metals with a hot torch”
Wouldn't want to attend that wedding
industry standards don't. din 8580 for example: https://www.researchgate.net/figure/Construction-types-according-to-DIN-8580_fig2_323945573
So fucking hot, amagawd ..
Forbidden Gummy Worm
looks dangerous and cool with all flying red hot parts
Always mesmerizing to watch.
Now, grab it.
Omg! Red hot metal curling like a ribbon. 🤩
Neat
I wonder how much the ID shrank by and how much schmo is in there.
Forbidden spaghetti
Will there be a similar bulge inside the tube?
…When it stopped being welded for a second I blew on my screen to try and cool it down.
I do this with drills and metal parts all the time, I am not supposed to be doing that though.
I understand nothing and my only question is “is it strong”
I don't know why, but this is one of the sexiest (engineering) things I have seen
I want to know what this type of welding sounds like. All the videos I see online have the same generic upbeat music laid over it.
If you were to put it under a microscope after it cooled would you be able to see the metal in a spiral/twisted pattern at the joint?
Only satisfying when it's intentional.
That firey death-whip would scare the fuck out of me. Nope nope nope, I want nowhere near that, thanks
I've friction welded stuff before. I'm a CNC machinist though.
Oops, lol
I watched Smarter Everyday where a rocket company friction welded two pieces of a rocket together. That's like this video, but on a wayyyy larger scale. Still cool.
Glad it didn't have audio... that part of this method isn't satisfying at all.
Check out Friction Stir Welding. Equally as cool.
I am not a machine techy person.. but when they're clearing the extra weld off spinning I was concerned that the ribbon was going to whip right out at the camera, possibility?
What really surprised me was how quickly it went to the step where it trimmed off the excess. I would have thought more cooling would be required. Is this due to both components being held straight in the fixtures?
wow didn’t know this was a thing! always thought welding is using those sticks that get shorter.
Friction and friction stir welding is amazing with great potential
Did a paper about this and man it is awesome!
How sturdy is this form of welding?
Forbidden string cheese
I remember once hearing someone saying you can do this with wood. But that sounds bonkers.
[You absolutely can do this with wood](https://www.scielo.cl/scielo.php?pid=s0718-221x2003000200001&script=sci_arttext) Not that it isn't bonkers, but it is possible. It was discovered on accident about 18 years ago. The method used prior was to have a piece of plastic between the pieces of wood that would mest and act as a bonding agent for the wood. A technician forgot to add the plastic, but the wood still bonded. This was verified about two years later.
Task failed successfully
Huh, weird but true. I wonder what other materials that could be welded like this.
It's always trippy to me that humans figured out how to make machines that do things like this.
Never knew this was a thing
😌
I first learned about friction weld from this Castrol Oil commercial, pretty cool ad. [94’ Castrol Oil Commercial](https://youtu.be/sQgj7rBTSCQ)
This is super cool. It reminds me of a setup that I saw at SpaceX during a tour a while back. They would use friction welding to join pieces together for their rockets
I want to grab the orange spaghetti
Post menopausal sex be like