Driveshaft friction welding

[Steve from Socal]

I have a driveshaft that I need to change a flange. The flanges are friction welded at the factory, these are steel shafts. I would like to have the replacement flange friction welded if possible. Are there shops with rotary friction welders that do one off work? The tube diameter is 65MM or 2.562

Steve

 

[raddksn]

are you just trying to copy the factory "look"? if not TIG or MIG will be plenty strong.

 

[Jess]

Check with a driveline shop. In my area there a several and they can repair, rebuild or manufacture pretty much anything you want. I have had several military driveshaft flanges changed for repowers and although not cheap, they are likely stronger than the original.

 

[sberry]

How is it friction welded? Most are automatic mig.

 

[Steve from Socal]

All the aluminum driveshafts are welded this way, Mercedes has used this process since the early 1980's on steel shafts.

Steve

 

[APEowner]

Friction welding setup is an iterative process that involves multiple weld attempt, destructive test cycles while it's getting dialed in so it's really not practical for a one time weld.

 

[600SL]

I have a driveshaft that I need to change a flange. The flanges are friction welded at the factory, these are steel shafts. I would like to have the replacement flange friction welded if possible. Are there shops with rotary friction welders that do one off work? The tube diameter is 65MM or 2.562

Steve

Hello Steve

Surprise I had to do the same thing. I wasn't able to get it friction welded but I got it welded and it works fine.

Sikorsky Aircraft used to friction weld the CH-53E main rotor spars to the hub attachment flange.

 

[600SL]

Stock and modified drive shafts. I have no idea why there are 2 welds. Maybe he made a mistake.

 

[R.Anderson]

Stock and modified drive shafts. I have no idea why there are 2 welds. Maybe he made a mistake.

Looks like it was cut and a piece added to make it longer.

 

[600SL]

Looks like it was cut and a piece added to make it longer.

Exactly except the drive shaft was shortened.

 

[Steve from Socal]

Well I guess I'll get some DOM tube as a sleeve and roll my own!

Steve

 

[600SL]

Well I guess I'll get some DOM tube as a sleeve and roll my own!

Steve

I had this guy do it.

https://www.facebook.com/RCVPerformance/?pnref=lhc

 

[Fcvapor05]

Are you saying you're going to try and friction weld a driveshaft flange at home? This is not a good idea.

 

[pi_guy]

It's not really welding it is more fusing.
Neat concept good for dissimilar metals. Not sure I have seen it used on a race car.

 

[Steve from Socal]

Are you saying you're going to try and friction weld a driveshaft flange at home? This is not a good idea.

NO,

I am going to weld a piece of DOM tubing on the flange and then weld the assembly onto the driveshaft tube. All my lathes have small spindle holes so I have to put the tube in a steady rest to line it up. The sleeve just make it easier to zero out.

I am going to play with the donor a bit and see if I can do a semi automatic weld with my mig.

Steve

 

[mhejl]

I had a similar situation and took mine to three local driveshaft shops in the DFW area. None of them would touch a friction-welded drive shaft. All could build a new one for around $300, though; the yokes are typically stocked items. I ended up buying a used one as I was in a hurry and the particular yoke I needed was special order.

 

[sberry]

We used conduit back in the day to repair some,,, ha.

 

[laydoubtFab]

Don't use DOM for making a shaft with, it turns expensive when trying to get it balanced later on. There is actual tubing available for making the shaft from, most suppliers call it Spicer tube.

 

[3 Gun Shooter]

Don't use DOM for making a shaft with, it turns expensive when trying to get it balanced later on. There is actual tubing available for making the shaft from, most suppliers call it Spicer tube.

Driveshafts use a special tubing, When ever I built a shaft, I would TIG weld the flanges on. I also put a lot of effort into straightening the shaft after. I've got shafts down to .002 run out, but .005 was OK. Then didn't take a lot to balance the shaft.

 

[Steve from Socal]

I will go through the steps on this as much as possible, I forgot to take pics at various steps!

Sberry, funny you mention conduit, I used some 2" conduit for the alignment sleeve. The conduit was bored and turned on the OD to remove as much imbalance as I could. The OD had to be sized anyway and boring the inside was a couple passes.

The driveshaft tube is just too big to pass through the spindle of any of my lathes so, I had to use a steady rest for the shaft cut. Everything is ready to weld up, I need to set up the welder and get it dialed in.

Steve

 

[e30bradley]

I shortened the driveshaft on the front on my 4x4 truck. I mig welded it and have tested it over 50mph in 4 wheel drive, I have also done quite a bit of snow plowing and other 4x4 work with it.