Friction Stir Welding
Friction stir welding, also known as Friction Stir Welding (FSW), is a welding technique that does not require a melting process. Instead, the materials are brought into a semi-solid state by heat, which is generated by friction between the component and a welding pin, and by applying pressure, whereby the molecules of two aluminum components are mixed.
This method allows two components to be permanently and tightly connected, with the connection having higher mechanical properties than the base material and being free of porosity. This allows otherwise non-demoldable geometries to be cast and then sealed with a lid or a cover. The technology is often used in components that carry media.
Advantages of Friction Stir Welding
High weld seam quality: FSW produces weld seams with high mechanical strength, good ductility, and low porosity. This leads to an overall better quality of the weld connection.
No melting required: Since the materials are not heated to the melting point, no melt-related defects such as cracks, pores, or impurities from foreign materials occur.
Environmentally friendly: FSW does not require filler materials or shielding gases, reducing environmental impact compared to traditional welding processes.
Low thermal distortion: Because the heat zone is limited and there is no massive heating and cooling, warping and stresses in the material are minimized.
Suitable for different material thicknesses: FSW can be used for a wide range of material thicknesses, making it very versatile.
Allows the connection of different materials: This method can be used to join different metals, which is often difficult with traditional welding techniques.
Automatable: The process can easily be automated, leading to consistent quality and higher production efficiency.
Good tool life: Despite the high mechanical stress during welding, the tools usually have a long service life, which reduces operating costs.
Applications
Aerospace industry: FSW is often used to weld aluminum alloys used in aircraft structures, such as fuselage and wing parts. The technique is particularly useful for materials that are difficult to handle when welding conventionally.
Automotive industry: In automotive manufacturing, friction stir welding is used to create lightweight metal constructions that contribute to weight reduction and thus to improving fuel efficiency. It is also used for aluminum engine blocks and transmission components.
Shipbuilding: In the manufacture of aluminum structures in ships, FSW is used to ensure high strength and corrosion resistance.
Railway industry: FSW is often used for the manufacture of aluminum car bodies and other structural components of trains.
Electronics industry: FSW enables the welding of heat sinks and other heat dissipation components, which are required in electronics for effective heat dissipation.
Energy engineering: This technique is also used in the manufacture of heat exchangers, which are used in various energy generation systems.
Construction industry: FSW is used for the welding of aluminum construction elements used in modern construction.
Suitable materials
The following materials can be welded together regardless of their processing method (such as rolling, die casting, or extrusion):
- Aluminum with aluminum
- Copper with aluminum
- Magnesium with magnesium
Our services
Our dedicated team offers customers comprehensive services for friction stir welding:
- Design and customization of parts specifically for the FSW process
- Development and manufacturing of special tools and fixtures for the FSW process
- Process optimization for mass production We are able to accompany the development of a part from the prototype phase to series production.