Inertia friction welding system for martensite-free joining of materials

A method for joining materials, comprising:

• (a) providing a first component, wherein the first component includes a first alloy having a known austenization temperature below which martensite forms when the component is heated and then cooled at a predetermined rate of cooling;
• (b) providing a second component, wherein the second component includes a second alloy, wherein the second component is a hex stud that further includes C464 brass, and wherein the second component includes an axis of rotation;
• (c) providing an inertia friction welding machine to create a weld between the first and second components without crossing the austenization temperature of the first alloy and forming martensite therein, wherein the inertia friction welding machine operates at a speed of 4000-4500 rpms, an inertial mass of 1.21 WK2, and a thrust load of about 5200-lbs force to 6000-lbs force, and wherein the weld is formed at a predetermined location on the first component;
• and
• (d) creating axial alignment between the first component and the second component at the predetermined location by modifying the inertia friction welding machine to include a removable tool, wherein the removable tool creates a surface plane on the first component at the predetermined location that is normal to the axis of rotation of the second component.