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Development and Validation of a Cost-Effective Rotary Friction Welding Machine by Repurposing a J23 Mechanical Press Frame

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Abstract:

This study presents the comprehensive design and fabrication of a bespoke laboratory-scale Rotary Friction Welding (RFW) machine, developed by repurposing a J23 mechanical press frame to provide a cost-effective research platform. The system integrates a 7.5 kW motor with VFD control for precise rotational speeds up to 1500 RPM and a two-stage hydraulic circuit to manage friction and forging pressures. To validate the machine's efficacy, twenty experimental runs were conducted on similar-material joints, specifically AISI 304 stainless steel, AA1050 aluminum, and AISI 1030 structural steel. Mechanical testing and microstructural analysis demonstrated that the system consistently produces high-integrity bonds, with AISI 1030 steel joints achieving 100% joint efficiency and AISI 304 samples reaching ultimate tensile strengths exceeding 800 MPa. The results confirm that the reoriented horizontal frame maintains the necessary axial alignment for high-quality solid-state joining, making it a reliable and accessible tool for academic investigation into RFW process optimization.

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Periodical:

Key Engineering Materials (Volume 1062)

Pages:

163-168

DOI:

https://doi.org/10.4028/p-g6Nb5g

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Online since:

August 2026

Authors:

Nguyen Dang Khoa, Pham Quang Trung*, Dinh Duy Khoa

Keywords:

AA1050 Aluminum, AISI 1030 Structural Steel, AISI 304 Stainless Steel, RFW Machine, Rotary Friction Welding (RFW)

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© 2026 Trans Tech Publications Ltd. All Rights Reserved

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References

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