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A comprehensive subcontract welding service, from start to finish

The beauty of Thompson Friction Welding’ subcontract welding services, is they are delivered using our own rotary friction welding machine technology, so you are guaranteed a quality weld, each and every time. We have capacity on several production machines at our Halesowen facility, that provide:

Weld range of Approx. Ø6MM to Ø120MM Solid Steel (Subject to Spec.) & Ø12MM to Ø219MM Tubular Steel (Subject to Spec.) – Up to 8M length capacity – Quality Assurance – 100% In process Monitoring – Weld Playback – Automatic Machine Lockout – Orientation Capability – Induction Post Weld Heat Treatment with 100% monitoring – Pre & Post Weld Processing Ferrous and Non Ferrous – Online turning external flash removal – Component ID Marking – Procurement & Stocking – Call Off Orders

The question that engineers

Thompson Friction Welding

The question that engineers and manufacturers ask: Can we do this better, cheaper and more efficiently?

The ability to join similar, dissimilar or exotic materials directly to each other with a high integrity bond is the holy grail of industrial manufacturing. But, what are the benefits of achieving this is, other than reduced cost?  An increase in product/weld quality, efficiency and reliability are all valid considerations.

For OEM’s competing in the global market place and who need to establish their positions with innovative, quality and cost effective products, access to established and proven subcontract friction welding service, is key.

KUKA UK subcontract friction welding offers world-leading expertise in both the friction welding process but also, as the OEM of Thompson friction welding machines, the largest subcontract facility in the UK. Offering in-house testing and on-site metallurgical services with a fully equipped metallurgical laboratory.

But what materials can be joined using the Thompson rotational friction welding subcontract provision? See our informative table below, or reference the ‘magic-wand’ for a quick and easy pictorial reference of weld capabilities.

Capital investment

Your subcontract needs, in safe hands

Overcoming capital costs Providing your customers a level of service you can be assured of, without the need for capital investment

Thompson’s UK AWS sub-contract facilities located in Halesowen, West Midlands provide a full range of friction welding and support services for those customers and applications that cannot justify the capital investment but who still want to benefit from the process to grow their businesses. Not only can Thompson AWS offer rotary friction welding on a subcontract basis, consultation, pre and post weld processing inclusive of specialist, induction heat treatment and metallurgical investigation and analysis via the fully kitted onsite laboratory is also available.

But what are the benefits of subcontracting your industrial joining requirements to Thompson? See below just some of the reasons to trust us with your welding needs.

100% parent material joints

Full bonding across the entire contact area

Solid state process retaining parent material properties

Fine grain structure: no porosity and minimal hardening

Superior joint strength

Very low risk for safety critical joints

The only direct method of joining for cu-al and other bi-metallics

Machine stored parameters offer 100% repeatability & reliability

Automated joining process with 100% in-process monitoring

Comprehensive quality assurance

Fast weld times

Economical per unit cost

Flexibility to weld wide range of similar & dissimilar materials

Friction welding dissimilar metal combinations.

One key differentiator between friction welding and other welding methods is the capability to join dissimilar metal combinations. By using rotary friction welding to do this is a cost effective way to get the best from both materials, whilst achieving a homogenous bond. The above table illustrates some of the common bi-metallic combinations that Thompson Friction Welding are able to achieve, using our industry leading friction welding machine technology.

Value-add laboratory services

KUKA’s metallurgical investigations range from straightforward elemental analysis to in-depth studies of failure or fracture mechanisms, a series of visual, metallurgical and mechanical inspections and checks for instance, hardness surveys, micro and macro inspection, mechanical testing including bend testing and tensile testing.

We also offer materials selection advice, assessing their suitability for friction welding and recommending improvements where appropriate. Just some of the benefits attributed to our in-house laboratory services are detailed below.

Mechanical Testing

Hardness & Micro Hardness Testing

Sample Preparation & Etch

Macro & Micro Analysis

Optical Microscopy

Stereo Microscopy

SEM

Joint Integrity Analysis

Coating Analysis

Third Party Investigation & Analysis

Materials suitability advice

Materials treatment advice

Friction Welding Process Advice

The Process

Rotary friction welding is in fact bonding, or forging. Components are heated until they plasticise, then forged together. A solid state bond is achieved as the materials cool.

 

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Rotary friction welding

TFW Machines

The TFW concept has remained the same, though several value-add features, such as flash removal, automation and flexi-base technology compliment our portfolio.

 

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PLC Thompson plate

A Global Presence

With over 1,000 machines used in manufacturing, globally, Thompson is a trusted brand, with offices in the UK and in the USA.

 

 

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Hydraulic applications – cylinders and piston rods caret-down

Piston Rod

 

The Thompson PR direct drive series is specially designed to friction weld piston rods and cylinders for both OEM and Tier 1 manufacturers. These machines are used by many of the leading names in the yellow & green goods industry, cylinder manufacturing companies as friction welding is a repeatable, robust and accurate process.

Compared to conventional welding techniques, friction welding requires no consumables (gases and wire) or skilled operators.

The Thompson PR series is highly versatile, not only meaning pre-chromed piston rods, eyes and clevises, but also hydraulic cylinder caps and flanges can be joined on a single machine. The machines are easy-to-use, offering intuitive, tailor-made HMI process control software, wide range of flexible work holding solutions and variety of efficiency enhancements.

To download our piston rods and cylinders leaflet, go to our download centre.

 

 

Exploration applications – drill rods & pipes caret-down

The Thompson DP direct drive series is specially designed to friction weld all types of drill pipes and drill rods. Configured with application relevant options such as ID and OD flash removal solutions, ultralight quick-change tooling, infinite length capability and standard automation packages. The DP series has been the choice of many worlds leading manufactures of drill pipe and drill rods.

Direct drive friction welding offers the best possible bond coupled with a repeatable, robust and accurate process. All machines are equipped with the highly acclaimed intuitive Thompson Welder software offering total traceability.

The machines benefit from an open architecture design making them easy to automate. KUKA UK also offer a range of dedicated robotic automated solutions for load/unload.

To download our drill pipes and drill rods leaflet, go to our download centre.

 

Truck & Bus applications – drive & trailer axles caret-down

Friction welding axles

The Thompson AX direct drive series solutions are the choice of axle manufacturers worldwide. The solution is available in double ended (DE) or single ended (SE) configurations and includes features such as flash or upset removal, component marking for total traceability and dedicated automation packages.

The DE machines are available in three different sizes to accommodate light, medium and heavy-duty axles. They can also be configured to accommodate either drive or trailer (beam) axles with removeable support tooling for the axle housing. Featuring a unique flexibed design the machines have proven to offer fast cycle times along with being robust, accurate, reliable and repeatable.

The machines benefit from an open architecture design with no visible tie bars making them easy to automate. KUKA UK also offer a range of dedicated robotic automated solutions for load/unload.

To download our drive and trailer axles leaflet, go to our download centre.

 

Bi Metallics – Connectors for the electrical industry caret-down

friction welding example

The Thompson EC direct drive series solutions are specifically configured for joining bi-metallics for electrical connectors. Common applications include power distribution, rail, EV vehicles and lightning conductors for the construction industry. Friction welding has been proven to offer the best bond in terms of integrity and conductivity for material combinations such as copper to aluminium where traditional fusion methods are not an option.

Thompson EC machines commonly feature quick change work holding solutions, pre-weld part preparation and fast cycle times.

The machines benefit from an open architecture design with no visible tie bars making them easy to automate. KUKA UK also offers a range of dedicated robotic automated solutions for load/unload.

To download our connectors for the electrical industry leaflet, go to our download centre.

 

Other Applications caret-down

Cylinders

The machines benefit from an open architecture design with no visible tie bars making them easy to automate. KUKA UK also offers a range of dedicated robotic automated solutions for load/unload.

To download our piston rods and cylinders leaflet, go to our download centre.

Customer Case Studies

Opinions and experiences of customers that use Thompson friction welding machines

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The TFW Blog

Insights, updates and conversation across the TFW brand

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