Abstract: A method and system of inertia friction welding that enables the production of inertia friction welds in which the final upset can be controlled to an operator specified target. The method utilizes any profile-based upset control technique, including but not limited to torque modulation and pressure (load) modulation. The method dynamically modifies the profile upset setpoints to systematically drive the upset formation to produce a weld with the targeted upset. The method and system also enables the production of inertia friction welds in which the final welded part length can be controlled to an operator specified target. The system and associated method comprises inertia friction welding a pair of sample parts to form a sample weld while acquiring data relating to the formation of the sample weld.

Abstract: A method and apparatus for welding a first workpiece which is to be joined to a second workpiece, with said first workpiece extending within or through the second workpiece. The apparatus includes a rotatable workpiece drive member, a workpiece holding fixture for securing at least one other workpiece in position relative to the first workpiece and a radial support for the first workpiece that is separate and spaced from the drive member. Among the preferred embodiments disclosed for providing the radial support are a tailstock supporting sleeve arrangement, collet chucking, and roller type steady rests.