Friction Welding
Joining of different materials

Friction Welding

The friction welding process belongs to the group of pressure welding processes. The friction welding process is divided according to the type of relative movement and the type of energy used. Typical processes are friction stir welding, orbital friction welding, rotary friction welding. During the welding process, the components to be welded move relative to each other. The parts to be joined are brought together at the contact surfaces and heated by translational and rotational movements. Once the process temperature has been reached, the parts are plastically deformed under great force. The rotation stops, and the force applied is increased and maintained so that the parts to be joined form a material bond.

The special feature of this process is the flexibility to combine a wide variety of materials. The technology of friction welding is known for a secure and economical connection of different materials.

Friction welding system and annealing system at Zipp Industries

Zipp Industries GmbH & Co. KG uses the process of rotary friction welding with continuous drive. We weld our manufactured threaded connectors with the base bodies of our rotary augers or rotary drilling pipes. With our friction welding machine, we can weld different lengths, diameters, wall thicknesses and materials together. The cooling after the friction welding process takes place very quickly, causing stresses in the weld metal and the heat-affected zone. In order to eliminate these stresses, our welded products are stress-relieved in an annealing process. 

We heat the pipe specifically at the weld seam and ensure that the stresses that have arisen are reduced. The diffusion processes are completed in the holding process. After the diffusion processes are completed, the product is specifically cooled. After completion of the annealing process, the welded joint is stress relieved.

In addition, we offer you friction welding for your individual welded joints in contract work. Our own friction welding system allows us a high degree of flexibility when confirming delivery dates.

Advantage of friction welding

  • short welding time, very fast process
  • flexible lot sizes
  • excellent welding quality
  • clean production
  • no additional materials
  • low material loss
  • optimal strength values in the weld seam (after annealing treatment)
  • high quality standard through good reproducibility of the welding parameters through process monitoring and logging
  • Final inductive heat treatment for stress-free welds. Delivery program & service

Delivery program & service

  • Production of test pieces
  • Series and individual production orders
  • Documentation of each weld


  • Standard diameters from 51 mm to 177.8 mm
  • Lengths from 0.5 meters to 6.0 meters

A short video on the subject of friction welding

Set-up of the friction welding system at Zipp Industries

Joining dissimilar metals by friction welding

Our products are made of different materials. Our pipe material usually consists of S355J2+N structural steel, which is easy to machine and has excellent weldability. The connectors are made of 42CrMo4. The alloy steel has high strength, high toughness, good hardenability and high fatigue strength.

As a rule, any forgeable metal can also be friction welded. Although a copper-aluminum joint is generally considered non-weldable, it is possible to create a durable joint using the friction welding process. Machined, sawn or sheared surfaces can be connected by friction welding without complex surface treatment.

Heat treatment with induction

In order to reduce the tension in the material caused by the friction welding process, we heat the already processed metal workpieces and the weld seams in a targeted manner with our annealing system by induction.

Induction is a flameless, non-contact heating method that can heat a defined area, such as the weld and adjacent heat-affected zone, within seconds after friction welding without touching the component. A magnetic field forms around the inductor. This magnetic field heats the material specifically at the weld seam since the inductor is placed specifically at the weld seam.

The holding process keeps the temperature constant for a defined period of time so that the diffusion processes are completed, and the stresses are reduced and brought to a normal level.
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