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Mar. 25th ’24 – Going Green with Friction Welding: A Sustainable Choice for Manufacturers

The Future is Sustainable – Friction Welding Excels in Eco-Friendly Manufacturing Why Friction Welding is a Breath of Fresh Air

In today’s environmentally conscious world, manufacturers are constantly seeking ways to reduce their environmental impact. Friction welding emerges as a champion in this pursuit, offering a sustainable joining solution that minimises waste, conserves energy, and aligns perfectly with modern environmental standards.

Minimising Material Waste

Traditional joining methods like arc welding often generate significant scrap material. Friction welding, however, takes a different approach. It utilises heat and pressure to create a solid-state bond without melting the metal. This eliminates the need for filler materials or lost metal due to spatter, significantly reducing overall material waste.

Imagine the environmental impact! Less waste translates to a lower demand for raw materials, minimising the environmental footprint associated with mining and transportation. Additionally, by using less material, manufacturers can potentially reduce the weight of their final products, leading to further benefits in terms of transport efficiency.

Energy Efficiency

Friction welding boasts impressive energy efficiency compared to conventional welding techniques. Here’s why:

  1. Localised Heat Generation: Friction welding focuses heat generation on the specific area being joined, minimising overall energy consumption.
  2. No Need for Preheat or Post-Weld Heat Treatment: Unlike some welding methods, friction welding eliminates the need for preheating or post-weld heat treatment, further reducing energy requirements.

By minimising energy consumption, friction welding contributes to a significant reduction in greenhouse gas emissions associated with electricity generation. This aligns perfectly with modern environmental standards and helps manufacturers meet their sustainability goals.

Clean and Green: A Sustainable Choice

Friction welding offers several additional eco-friendly advantages:

  1. No Harmful Fumes or Gases: The process doesn’t involve the use of fluxes or shielding gases, eliminating the release of harmful fumes and air pollutants. This creates a cleaner and healthier working environment for employees and minimises the overall environmental impact.
  2. Reduced Noise Pollution: Compared to arc welding’s loud noises, friction welding generates significantly less noise pollution, contributing to a quieter and more pleasant work environment.

Aligning with Modern Environmental Standards

Friction welding aligns seamlessly with modern environmental regulations and sustainability initiatives. As industries strive to reduce their carbon footprint and minimise waste, friction welding provides a solution that meets these critical requirements. Additionally, the process helps manufacturers comply with environmental regulations related to air quality and noise pollution.

Beyond Sustainability

The environmental benefits of friction welding are just one piece of the puzzle. This innovative technology also offers advantages like:

  1. Stronger, More Reliable Welds: Friction welding creates exceptionally strong and reliable bonds, leading to longer-lasting products and a reduction in the need for replacements.
  2. Faster Weld Times: Compared to traditional methods, friction welding offers faster weld times, improving production efficiency and reducing overall energy consumption per weld.

The Future is Sustainable: Friction Welding Leads the Way

As the manufacturing industry embraces a more sustainable future, friction welding stands out as a powerful and versatile solution. By minimising waste, conserving energy, and reducing emissions, it empowers manufacturers to operate with a lower environmental impact. From a cleaner production process to longer-lasting products, friction welding offers a win-win situation for both businesses and the environment.

Ready to Embrace a Sustainable Future?

If you’re looking for a way to reduce your environmental impact and enhance your manufacturing processes, Thompson Friction Welding can help. Contact us today to learn more about how friction welding can contribute to your sustainability goals.

Mar. 11th ’24 – From Halesowen to the World: Thompson Friction Welding’s Legacy of Strength

Diamond Anniversary: Celebrating 60 Years of Innovation at Thompson Friction Welding! Building a Brighter Future: Friction Welding’s Role in a Sustainable Industry

A Diamond Anniversary for a Pioneering Company; From Halesowen to the World

Thompson Friction Welding embarked on a remarkable journey, forever transforming the landscape of metal joining. As we celebrate our diamond anniversary, we look back with immense pride on our rich heritage of innovation and unwavering commitment to excellence.

The story of Thompson Friction Welding began in Halesowen, West Midlands, UK. Driven by a vision to push boundaries and create a superior joining method, the company quickly gained recognition for its pioneering spirit and dedication to quality.

Celebrating Our People: The Backbone of Our Success

Our greatest asset throughout these six decades has been our incredible team. From our engineers and designers to our production specialists and customer service representatives, the dedication, expertise, and unwavering spirit of our employees have made Thompson Friction Welding the success story it is today.

Looking Ahead: A Brighter Future with Friction Welding

The 60th anniversary is not just a celebration of the past; it’s a springboard for the future. Thompson Friction Welding is poised to continue its legacy of excellence, fuelled by a passion for innovation and a commitment to building a stronger, more sustainable future. With our extensive experience, unwavering dedication to customer satisfaction, and commitment to continuous innovation, we are confident that Thompson Friction Welding will remain a leader in the field of friction welding for generations to come.

We invite you to join us on this exciting journey!

Mar. 5th ’24 – Real-World Applications: Friction Welding in Action Across the Rail Industry

Forging a Stronger Rail Network: The Advantages of Friction Welding Technology Shaping the Future of Rail: Advancements in Mobile Systems, Quality Control, and Material Compatibility

Friction Welding: A Powerful Ally for a Stronger, More Sustainable Rail Network

In the ever-evolving realm of rail transportation, ensuring robust and reliable infrastructure is paramount. From high-speed passenger trains to the workhorses of freight transportation, every component plays a critical role in guaranteeing smooth, safe, and efficient operation. In this crucial arena, friction welding emerges as a powerful ally, offering unparalleled strength, improved efficiency, and a path towards a more sustainable rail industry.

Traditional methods like bolted or flash-butt welded rail joints can develop weaknesses over time, potentially leading to infrastructure failures and service disruptions. Friction welding, however, presents a superior solution. By generating heat and pressure without melting the material, it creates a solid-state bond that is exceptionally strong and virtually free of the drawbacks associated with conventional techniques. This translates to:

  1. Enhanced joint integrity: Friction welds exhibit superior strength compared to traditional methods, minimising the risk of joint failure and ensuring a longer lifespan for rails.
  2. Reduced maintenance requirements: Stronger welds translate to less frequent inspections and repairs, leading to significant cost savings for rail operators.
  3. Improved safety: The robust nature of friction welds contributes to a safer rail network by minimising the risk of track-related incidents.

Friction Welding: A Catalyst for Efficiency and Sustainability

Beyond its undeniable strength benefits, friction welding offers significant advantages for the rail industry in terms of efficiency and sustainability:

  1. Faster weld times: Compared to traditional methods, friction welding boasts significantly faster weld times, minimising track downtime and accelerating infrastructure projects.
  2. Reduced energy consumption: The localised heat generation of friction welding translates to lower energy consumption compared to flash-butt welding, contributing to a more environmentally friendly approach.
  3. Improved weld consistency: The controlled process of friction welding ensures consistent weld quality across the entire rail network, leading to reliable performance.

Real-World Applications: The Power of Friction Welding in Action

Friction welding is already playing a critical role in various rail applications:

  1. Joining New Rails: Friction welding is increasingly used to join new rails, creating longer, seamless tracks that require less maintenance.
  2. Repairing Existing Rails: Worn or damaged rails can be effectively repaired using friction welding, extending their lifespan and reducing the need for complete replacements.
  3. Manufacturing Rail Components: Friction welding is utilized to manufacture various rail components, including switches and crossings, with enhanced strength and durability.

The Future of Rail: A Brighter Track Ahead

As the rail industry strives for increased efficiency, sustainability, and safety, friction welding holds immense potential. With ongoing research and development, we can expect further advancements in:

  1. Mobile friction welding systems: Developing mobile systems for on-site rail welding, minimising downtime and enhancing efficiency.
  2. Advanced quality control techniques: Implementing cutting-edge methods to ensure the highest quality and consistency of friction welds.
  3. Welding dissimilar materials: Expanding the capabilities of friction welding to join various rail materials, offering greater design flexibility.

Thompson Friction Welding: Partnering for a Stronger Future

At Thompson Friction Welding, we are committed to delivering innovative friction welding solutions that empower the rail industry. With our expertise and dedication to quality, we are proud to be a partner in building a stronger, more efficient, and sustainable rail network for the future.

Feb. 21st ’24 – Shaping the Future of Aerospace, One Weld at a Time

Taking Flight with Friction Welding: How Innovation Strengthens the Aerospace Industry Lighter, Stronger, and More Efficient Aircraft

The aerospace industry thrives on innovation, constantly pushing boundaries to achieve lighter, stronger, and more fuel-efficient aircraft. In this pursuit, friction welding emerges as a powerful ally, playing a crucial role in enhancing the structural integrity of components, minimising weight, and maximising fuel efficiency. Let’s delve into how this transformative technology is taking flight in the world of aerospace.

Beyond Rivets and Bolts: A Stronger Bond for Greater Integrity

Traditional methods like rivets and bolts often limit aircraft design due to stress concentrations and potential fatigue issues. Friction welding, however, offers a revolutionary solution. By generating heat and pressure without melting the materials, it creates a solid-state bond that is exceptionally strong and free from the weaknesses of traditional methods. This translates to:

  1. Improved fatigue resistance: Friction welds can withstand significantly higher cyclic loading compared to riveted joints, resulting in longer component lifespans and enhanced structural integrity.
  2. Reduced stress concentrations: The seamless nature of friction welds eliminates stress concentrations typically associated with rivets or bolts, further improving structural performance.
  3. Enhanced reliability: The robust bonds formed through friction welding minimise the risk of joint failure, leading to safer and more reliable aircraft operation.

A Lighter Touch: Taking Weight Off Without Compromising Strength

The aerospace industry constantly strives for weight reduction, as every gram saved translates to increased fuel efficiency and longer flight ranges. Friction welding plays a key role in this pursuit by enabling the use of lighter materials:

  1. Joining dissimilar metals: Friction welding facilitates the joining of lightweight metals like aluminium and titanium, which offer superior strength-to-weight ratios compared to traditional materials like steel.
  2. Minimising material waste: The localised heat generation of friction welding allows for near-net-shape manufacturing, minimising material waste and further reducing overall weight.
  3. Optimised designs: The ability to join complex shapes precisely opens doors for innovative, lightweight designs that wouldn’t be possible with traditional methods.

Fuel Efficiency Takes Off: Every Gram Counts

The weight reduction achieved through friction welding directly translates to improved fuel efficiency. Lighter aircraft require less fuel to achieve the same level of performance, resulting in:

  1. Reduced operating costs: Airlines can benefit from significant cost savings due to lower fuel consumption.
  2. Environmental benefits: Lower fuel consumption translates to reduced carbon emissions, contributing to a more sustainable aviation industry.
  3. Increased range: Lighter aircraft can travel further distances on the same amount of fuel, opening up new routes and opportunities.

Real-World Examples: Soaring High with Friction Welding

The impact of friction welding is evident in numerous real-world applications:

  1. Airbus A350 XWB: This next-generation aircraft utilises friction welding extensively in its wings and fuselage, contributing to its impressive weight reduction and fuel efficiency.
  2. Boeing 787 Dreamliner: The Dreamliner’s fuselage panels are joined using friction welding, resulting in a lighter structure and improved fuel performance.
  3. Engine components: Friction welding is increasingly used in jet engine components like compressor blades and blisks, leading to enhanced strength and reduced weight.

The Future of Flight: A Brighter Horizon with Friction Welding

As the aerospace industry continues its quest for lighter, stronger, and more efficient aircraft, friction welding promises to play an even greater role. Ongoing research and development are focused on:

  1. Expanding material compatibility: Joining even more exotic and lightweight materials for further weight optimisation.
  2. Automating processes: Developing automated friction welding systems for increased efficiency and consistency.
  3. Advanced quality control: Utilising cutting-edge techniques to ensure the highest quality and reliability of friction welds.

Friction welding is not just shaping the future of the aerospace industry; it’s taking flight with it. By offering unparalleled strength, reduced weight, and improved efficiency, this transformative technology is helping aircraft soar higher, further, and with a lighter environmental footprint.

Feb. 5th ’24 – Unveiling the Secrets of a Strong Weld

Guaranteeing Quality in Friction Welding: Unwavering Reliability Through Testing From Visual Inspections to Microscopic Scrutiny

In high-stakes applications where failure isn’t an option, trust becomes paramount. For friction welding, this trust relies on meticulous quality control measures that ensure the unwavering reliability of each joint. Today, we’ll delve into these rigorous testing practices, revealing the steps taken to guarantee the integrity and performance of every welded component.

Friction welding, while visually impressive, goes far beyond just heat and pressure. To guarantee the strength and performance of welded parts, a series of non-destructive testing (NDT) techniques are diligently applied. These inspections act as silent observers, meticulously examining the weld for any potential issues. Visual inspections, dye penetrant testing, and radiographic examination become the first line of defence, scrutinising surface irregularities, minute cracks, and internal imperfections.

But the journey doesn’t stop there. To truly understand the strength of a friction weld, quantitative testing methods come into play. Bend testing subjects the joint to controlled bending forces, revealing its capacity to withstand deformation without breaking. This crucial test, mirroring real-world stresses encountered in various applications, assesses the weld’s flexibility and resilience.

Truth Under Tension and Seeing Beyond the Surface

Finally, tensile testing applies a steadily increasing pull until the joint reaches its breaking point. This test, akin to a tug-of-war between the two welded metals, determines the ultimate tensile strength – the maximum force the joint can withstand before fracturing. It’s a crucial measure of raw strength, providing invaluable insights into the joint’s ability to bear significant loads.

For added assurance and deeper insights, some companies go beyond standard inspection methods. For example, our respected metallurgical laboratory at Halesowen utilises super-strength microscopy. This advanced technique offers a magnified view of the weld’s microstructure, revealing even the subtlest details. Grain structure, potential porosity, and the intricate fusion between the joined materials are all exposed. It’s like having a microscopic detective meticulously examining the scene, ensuring the bond is truly seamless and robust.

These rigorous testing protocols, from NDT to bend and tensile tests, combined with the power of super-strength microscopy, paint a clear picture of a weld’s true character. Every joint undergoes this meticulous scrutiny, ensuring the utmost reliability for critical applications. It’s a relentless pursuit of quality, a testament to the commitment to exceeding industry standards and building trust, one weld at a time.

Jan. 29th ’24 – Technological Advancements Broaden Application Range and Control

Friction Forging the Future: Emerging Innovations in Metal Joining Material Compatibility Expands to High-Strength Alloys

Gone are the days of friction welding being viewed solely as a niche joining technique. This dynamic process is undergoing a renaissance, fueled by innovative advancements that broaden its capabilities and enhance its efficiency. Today, we explore these emerging developments, revealing how they are shaping the future of metal joining.

Technological Leap

Friction welding is no longer confined to traditional methods. Techniques like linear friction welding, ideal for dissimilar metals, and rotary friction welding with axial feed are pushing the boundaries of material compatibility and control. Additionally, friction stir welding with linear motion promises laser-like accuracy for joining long, straight sections.

Material Metamorphosis

The materials you can bond with friction welding are no longer limited. From high-strength steels and lightweight alloys to exotic materials like titanium and zirconium, the scope has vastly expanded. Tailored process parameters and innovative tool designs are unlocking a world of joining possibilities.

Automation Incoming

Robotics are entering the welding scene! Advanced sensor technology and automation empower robots to meticulously prepare surfaces, control parameters with precision, and even conduct real-time weld quality checks – all without human intervention. This marks a pivotal shift towards hands-free, hyper-efficient welding.

Embracing the Revolution

By embracing these groundbreaking advancements, manufacturers can unlock a number of advantages:

  1. Enhanced efficiency and productivity
  2. Elevated product quality and reliability
  3. Reduced costs and environmental impact

The future of metal joining is illuminated by the brilliance of friction welding innovation. Join the revolution, explore the possibilities, and witness this once-unassuming process rewrite the script of industrial fabrication.

Jan. 24th ’24 – Joining the Future: Friction Welding is Transforming Diverse Industries

Weld Smarter, Not Harder: How Friction Welding Revolutionises Manufacturing No More Grinding Away at Profits: Our Clean and Efficient Edge

In the fast-paced world of manufacturing, every penny and every second counts. That’s why finding efficient and cost-effective production methods is a constant pursuit. When it comes to joining metals, the traditional methods like arc welding often leave businesses battling budget and time constraints. But there’s a rising star in the welding scene that’s changing the game: friction welding.

So, how exactly does friction welding deliver an edge in cost and time efficiency? Let’s dive into its superpowers:

Reduced material waste: Forget about mountains of slag and excess weld bead. Friction welding’s solid-state process creates near-perfect joints with minimal material loss. This translates to up to 15% material savings compared to arc welding methods, meaning more bang for your buck and less impact on the environment.

Shorter cycle times: Unlike arc welding’s slow heat build-up and cool-down, friction welding’s precisely controlled friction and pressure generate heat quickly and efficiently. This translates into significantly faster weld cycles, often 50% to 70% quicker than traditional methods. That means more parts produced in less time, boosting your operational throughput and competitiveness.

Eliminated post-weld cleanup: No more grinding away at slag and uneven weld beads. Friction welding’s clean joints require minimal, if any, post-weld finishing. This cuts down on labour costs, reduces machine wear and tear, and gives your finished product a sleek, professional look.

Real-world examples

Witnessing the power of friction welding is one thing, experiencing it is another. Take, for instance, a UK-based manufacturer of high-performance aerospace components. By switching to friction welding for joining titanium parts, they reduced material waste by 12%, cut cycle times by 60%, and eliminated costly post-weld finishing, saving them a whopping £250,000 per year.

And not just for aerospace giants, friction welding shines in everyday applications too. A small engineering firm in Wales used it to join dissimilar metals for their innovative bicycle frames. The result? Super-strong, lightweight frames made in record time, giving them a competitive edge in the market.

Technical insights

But what gives friction welding this edge? Well, it all boils down to science. The controlled friction and pressure generate heat at the interface of the parts, causing a thin layer of metal to soften and “mix” together, creating a strong bond without melting. This solid-state process eliminates the risks of porosity and liquation cracking associated with traditional welding, resulting in high-quality, reliable joints.

The verdict

When it comes to cost and time efficiency, friction welding isn’t just keeping up with the competition, it’s leaving it in the dust. With its ability to save material, accelerate production, and minimise post-weld work, friction welding is proving to be the weapon of choice for manufacturers who want to stay ahead of the curve. So, if you’re looking to optimize your welding processes and sharpen your competitive edge, look no further than the friction revolution.

Jan. 15th ’24 – Exploring the Versatility of Friction Welding

Unveiling the Fusion: Material Compatibility in Friction Welding And Insights Into Halesowen’s Metallurgical Laboratory

Explore the practical versatility of friction welding, where various materials seamlessly unite to form robust joints. Discover how this technique plays a pivotal role in crafting components for critical applications, known as bi-metallics. And gain insights into Halesowen’s metallurgical laboratory, where we ensure top-tier validation for our customers.

 

Diverse Materials, Robust Joints

Friction welding effortlessly blends materials, from robust steels and lightweight aluminium to exotic metals like titanium and zirconium. This versatility enhances the structural integrity of components, perfect for critical applications. For example, in aerospace, friction welding combines titanium and nickel alloys for enhanced strength. In the medical industry, devices are made with seamless joints that unite stainless steel and titanium, ensuring precision and reliability in life-saving procedures.

 

Halesowen’s Metallurgical Validation

Halesowen’s metallurgical laboratory stands as the cornerstone in ensuring the reliability of friction welding joints. This dedicated facility conducts meticulous testing and in-depth analysis, ensuring that each joint undergoes rigorous scrutiny. From evaluating structural integrity to assessing the precision of the welding process, the laboratory validates the quality and performance of friction-welded components. This commitment to thorough testing ensures that the bi-metallic components produced meet the highest standards, delivering top-tier reliability for our customers across diverse industries.

Dec. 15th ’23 – Effortless and Efficient: Friction Welding’s Automated Process for Consistent Quality

A Proven Technique for Critical Applications From Aerospace to Automotive, Friction Welding Delivers Superior Joints

Friction welding, a solid-state joining process, has emerged as a game-changer in the manufacturing of critical components across diverse industries, including aerospace, automotive, and medical. Its unique ability to produce strong and consistent welds has made it a preferred choice for demanding applications where reliability and performance are paramount.

 

Strength and Durability

Friction welding creates a metallurgical bond between the two materials, resulting in a joint that is as strong or stronger than the base materials themselves. This eliminates the weaknesses inherent in conventional fusion welding processes, such as hot cracking and liquation defects.

Dissimilar Metal Joining

One of the most significant advantages of friction welding is its ability to join dissimilar metals, a capability that is often challenging or impossible with other welding techniques. This opens up a wide range of design possibilities and allows for the creation of lightweight but strong components using the most suitable materials for the application.

Automation and Efficiency

Friction welding is highly automated, reducing the risk of human error and ensuring consistent weld quality. The process is also inherently energy-efficient, requiring less power compared to fusion welding methods.

No Consumables Required

Unlike fusion welding, which often utilises consumables like filler metals, fluxes, and shielding gases, friction welding eliminates the need for these auxiliary materials. This not only simplifies the process but also reduces costs and environmental impact.

Minimal Surface Preparation

Friction welding can be performed on parts with minimal surface preparation, such as machined surfaces, saw cuts, or even sheared edges. This reduces machining time and labour costs, contributing to overall cost savings.

Near-Net Shaping

Friction welding can be used to join parts with complex geometries, including thin-walled structures, without the need for extensive machining. This enables the production of components with minimal post-welding processing, further reducing costs and production time.

Environmentally Friendly

Friction welding is a clean and environmentally friendly process, with no fumes or harmful emissions generated. This aligns with the growing trend towards sustainable manufacturing practices.

Durable and Long-lasting Components

Friction-welded joints are known for their exceptional durability and resistance to fatigue, corrosion, and wear. This makes them ideal for applications where long-lasting performance is crucial, such as aerospace components and medical implants.

Cost-Effective Production

The combination of automation, efficiency, and minimal consumable usage makes friction welding a cost-effective process compared to other welding techniques.

Reduced Waste and Material Loss

Friction welding promotes efficient material utilisation, minimising waste and scrap generation. This contributes to a more sustainable manufacturing approach.

Case Studies

Friction welding has found widespread application in critical components across various industries:

  1. Aerospace: Friction welding is used to join high-strength aluminium alloys for aircraft structures, engine components, and landing gear assemblies.
  2. Automotive: Friction welding is employed to join dissimilar metals like steel and aluminium for lightweight car bodies, powertrain components, and suspension systems.
  3. Medical: Friction welding is utilised to create implantable medical devices, such as joint replacements, bone plates, and dental implants, demanding exceptional strength, biocompatibility, and long-term durability.

Dec. 8th ’23 – Embarking on the Friction Welding Journey

Unveiling Techniques & Advantages And Adding Stir Welding in to the Mix!

In this exploration, we’ll delve into the diverse world of friction welding, dissecting techniques such as rotary friction welding, linear friction welding, and friction stir welding. Join us as we unravel the unique features and advantages that make each method a standout in the realm of material joining.

 

Rotary Friction Welding: The Power of Rotation

Unlock the strength behind rotary friction welding as components spin, generating friction that transforms materials into a unified force. This rotational prowess induces heat, melting the materials at their interface. This molten state enables the formation of robust joints, showcasing its efficiency in creating seamless connections across various industries.

 

Linear Friction Welding: Precision in Action

Witness precision in action with linear friction welding’s controlled back-and-forth movement between materials, offering excellent control. This movement induces the necessary friction for welding, leading to localised heating. The result is a precise and controlled process, ideal for applications demanding exacting standards and intricate components.

 

Friction Stir Welding: Stirring Up Innovation

Step into the innovative realm of friction stir welding, where a non-traditional approach stirs materials without the need for melting. A specially designed tool stirs the materials together at a molecular level, creating a solid-state joint. This method reduces heat impact, preserves material properties, and allows for seamless joining of dissimilar materials. Explore its role in shaping modern manufacturing, particularly in industries seeking a blend of strength and ingenuity.

Dec. 1st ’23 – Understanding Friction Welding: A brief guide

Getting You to Grips with the Process As Well as Breaking Down Rotary and Linear Friction Welding

Friction welding, a groundbreaking method in material joining, stands out for its diverse applications and inherent advantages. In this guide, we’ll get you acquainted with the fundamental principles while highlighting pivotal techniques, namely rotary and linear.

This innovative process, mastered by TFW, distinguishes itself by utilising mechanical friction to generate localised heat for material bonding. Unlike traditional methods reliant on external heat sources, friction welding achieves plasticisation through the friction generated between the materials.

 

Rotary Friction Welding:

Imagine two components spinning against each other, creating friction where they meet. This friction generates heat, turning the materials molten and allowing them to weld together. This rotating technique is versatile and is utilised by industries, such as automotive and aerospace as well as gas and oil, to receive strong and reliable joints.

 

Linear Friction Welding:

Now, picture a back-and-forth, oscillating motion between two materials that are being held together. This movement creates the necessary friction for welding, offering precision and control. Linear friction welding is especially useful in applications where strict standards are crucial for the final product.

 

Applications and Benefits:

Friction welding finds widespread application across industries where robust and high-strength joints are critical. The process offers distinct advantages, including reduced heat-affected zones and the ability to seamlessly join dissimilar materials, making it a preferred choice in various situations.

 

History:

Understanding the historical context of friction welding adds depth to our appreciation, as it marks a transformative journey from its inception to becoming a sophisticated welding technique, shaping its modern applications.

Seeing as in 2023 Thompson celebrates 60 years of providing innovative friction welding, we’re proud to have our history entwined with that of a remarkable process.

Feb. 6th ’23 – Manufacturers start to eliminate the middle-man, by insourcing

Companies Develop In-house Operations Supply Chain Issues, Encourage Businesses to Manufacture Internally

One trend in 2022 that we’d all like we’d all like to forget about, is supply chain disruption – But, alas folks, it appears supply chain disruption is likely to be here for some time. Inflation is rising and with it, inflated raw material costs, not to mention labour shortages across the logistics landscape making sourcing materials almost unattainable for some businesses. The solution seems to be insourcing.

  1. In-house production eliminates the need to rely upon external supply chains, and may in fact be more cost-efficient than outsourcing. By insourcing, the manufacturer has control over where they may purchase raw materials and is able to react to demand more effectively than if there were reliant upon buying products in.

Insourcing also provides the perfect opportunity to expand upon manufacturing capabilities, extend product ranges and break into new markets.

Our customers purchase Thompson Friction Welding machines, not only based upon their accuracy, their speed or robustness, but as a means to develop a self-sufficient ecosystem, through which they are able to manufacture parts efficiently and cost effectively.

Here we have highlighted four of the reasons, customers purchase Thompson friction welding machines

  1. Flexible manufacturing
    Manufacturing in-house provides a greater level of flexibility –if a product needs to be changed for example. An outsourced product would need time, and costs, for changes to be made. The level of flexibility afforded by manufacturing inhouse, can ensure that changes to products don’t have an impact upon time, cost or manpower.
  2. Improved quality and traceability
    You have complete control over the quality products when manufactured in-house. It is is vital for businesses to practice quality control, especially in critical application components. Quality can be a problem when outsourcing – consider multiple products across an long chain of supply. By manufacturing in-house, you have complete control.
  3. Lower cost to manufacture
    Producing products in-house avoids many of the costs associated with outsourcing. Your business will need to manage your outsourced producers and supply chains, which involves manpower. By manufacturing products in-house, this element of management mis not required – less overheads to make your product.
  4. Complete control over your production!
    When manufacturing in-house, you retain control over product output. You are able to identify market behaviours, peaks and troughs and plan resources to meet demand.

At TFW we are seeing more activity from businesses who wish to bring manufacturing inhouse, both SMEs and larger enterprises, and we expect to see many manufacturers follow into 2023 as they explore innovative and exciting ways to turn current supply chain challenges into opportunities!

Investing in rotary friction welding technology can be a big task, but here at Thompson Friction Welding, we have an expert team on hand to advise and guide you through the process.

Why not come to our Halesowen facility and see the machines in action?