Material compatibility / Suitable materials for Friction Drilling

Which materials are suitable for friction drilling?

Friction drilling relies on material ductility and thermal conductivity. This page explains which materials are suitable and under which conditions they perform optimally.

What is friction drilling and how does it work?

To understand which materials are suitable, it’s important to first understand how friction drilling works. Friction drilling is a process where a specially designed drill bit uses heat and pressure to plastically deform the metal.

The material is displaced upward and downward, forming a strong collar and sleeve.

This allows you to create threaded holes in thin metal sheets or tubes without needing additional fasteners such as nuts or inserts.

Suitable materials

Friction drilling works excellently on metals that are ductile and have a lower melting point. The main suitable materials are:

Steel

Mild steel (S235): Commonly used in various applications. Frictiondrilling in S235 is no problem at all.
Stainless steel (304/316): Requires adjusted drilling parameters due to higher strength and heat generation. Local discoloration from heat is possible but can be treated with passivation techniques.
High-strength steel (e.g. 16MnCr5, 25CrMo4): Can be suitable with adapted process parameters. Some extreme types are not suitable. We’re happy to help you explore the possibilities.

Aluminium

Aluminium 6060-T6 and other aluminium alloys: All types of aluminium are suitable for frictiondrilling. This is due to the low melting and deformation temperature.

Note: we do recommend using our specially developed Aludrill.

Copper and brass

Copper and brass (CuZn39Pb3, CW614N): Is suitable for friction drilling, but requires adjusted parameters. Please contact us, we are happy to help you!

Less or non-suitable materials for friction drilling

Some materials or areas on profiles are less or not suitable for friction drilling due to their thermal or mechanical properties. However, there is sometimes a possibility or a workaround.

Materials with a low melting point

Lead, zinc, and tin: These materials melt too quickly under the high temperatures of the frictiondrilling process. Frictiondrilling is not recommended.
Zamak and other zinc alloys: Frictiondrilling is done in some cases, but the material is prone to cracking and deformation. Frictiondrilling is also not recommended here.

Extremely hard metals

Hardened steel (e.g. hardened 16MnCr5, hardened C45M): The material is too hard and causes excessive tool wear. Not suitable without special pre-processing. Contact us to discuss the possibilities.
High-strength steels such as HARDOX® and DP1000: Due to the extremely high strength of the material, there is not enough displacement to form a proper collar.

Brittle materials

Cast iron and zinc die-cast (GD-ZnAl4Co1): Metals with a brittle structure break easily under the pressure of frictiondrilling. Not suitable for a reliable connection.

Painted and coated materials

Some coatings and protective layers may be damaged during friction drilling.

Galvanized steel

On hot-dip galvanized surfaces, the zinc coating may flake off or become damaged during friction drilling.
With electrogalvanized steel, the underside of the formed bushing may crack. This can negatively affect the subsequent tapping process and the quality of the thread.

Powder coating and ED coating

Friction drilling after the coating has been applied may cause burn marks, discoloration or damage around the hole. Contact us to discuss the possibilities for your application.

Frictiondrilling on welded joints

Welding affects the material properties: Frictiondrilling directly on a weld seam can lead to cracking, a torn collar, and tool breakage. We do not recommend this.

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