STIRTEC Services

We support you from the initial idea all the way to series production. With feasibility studies, contract R&D, and FSW prototyping, we help secure your development process. We also take care of B- and C-sample production, provide targeted support in specification definition, and actively participate in the design of components.

In our technology center, we offer a wide range of complementary testing methods — from optical 3D measurements using GOM, to metallographic cross-section analysis and specific leak testing. Apart from that, we share our expertise through FSW training courses, multi-day workshops, and on-site operator qualification programs for your staff. Our IWE and FSW specialists are also available to provide you with expert support as technology consultants throughout your project.

The result: with Stirtec, you don’t just receive products — you gain a comprehensive partnership that ensures safety, efficiency, and innovation in every aspect of Friction Stir Welding.

- - FSW design assistance
  - Feasibility studies
  - Contract-R&D
  - FSW weld qualification according to ISO 25239:2020
  - Preparation of pWPS and WPQR
  - FSW prototyping & pre-serial production
  - Leak testing
  - Optical 3D measurements by GOM
  - FSW training & workshops
  - FSW operator training and qualification
  - Ramp-up support
  - 24h service support

FSW design assistance

Optimized components right from the start

With our FSW design assistance, we provide comprehensive support in the FSW-oriented design and engineering of your components — always with a clear focus on specific part requirements and future industrialization. We assist you in 3D modeling and project planning, and we apply our technological process know-how to ensure your components are optimally prepared for friction stir welding.

Our goal is to ensure stability and quality right from the early concept phase, minimizing potential sources of error and enabling cost-effective series readiness and industrial implementation from the very beginning. Through targeted consulting, practical recommendations, and innovative solutions, we make sure your projects are realized to be technically robust, efficient, and ready for the market.

Advantages of Friction Stir Welding (FSW)

Contract-R&D

Research and development as a service

We are your reliable partner for research and development – supporting you in tackling specific technological challenges, developing new products, or thoroughly evaluating the market readiness of an idea. Our experienced team combines FSW expertise, material knowledge, and process competence to implement innovative solutions in a practical and goal-oriented way.

Typical applications that can be reliably tested and validated with Stirtec:

- - Development of FSW joints for material combinations considered as hardly or non-weldable, such as aluminum with high-strength steel or copper.
  - Implementation of welding solutions for components with limited accessibility, where conventional methods reach their limits.
  - Feasibility studies and prototype development for complex hybrid materials still in the research or early development phase.
  - Validation and optimization of the friction stir welding process on components to ensure product quality and reproducibility.

We actively drive innovation in friction stir welding. We develop novel spot welding solutions (e.g. ContactStir®) and friction-based joining processes specifically tailored to the challenges of your components. These approaches not only optimize the welding process itself, but also enhance product performance, unlock new functionalities, and realize entirely new application possibilities. With Stirtec, you gain more than just insights — you gain concrete, actionable results that can directly feed into your product strategy.

Feasibility studies

Your entry for industrialization

The primary goal of a feasibility study is to confirm the fundamental suitability of a component for friction stir welding, identify specific areas for improvement, evaluate economic efficiency through maximum welding speeds, and outline the investment requirements for future series projects. Our feasibility studies include full FSW process parameterization, weld qualification according to relevant standards, and — depending on the component requirements — a detailed functional evaluation. We document all relevant welding parameters in detail, such as downforce, spindle speed, feed rate, and the interaction between FSW tool and clamping system affecting process stability. These investigations are complemented by accompanying distortion or leak tests, as well as metallographic cross-section analyses in accordance with FSW standard ISO 25239:2020.

At the end, we provide a technical project summary with an outlook and targeted recommendations serving as a solid basis for decision-making regarding further functional samples or prototypes: Which process windows are stable, which quality targets are achievable, and how your components can be efficiently manufactured in series production.

Through our active involvement, a feasibility study becomes not just a successful project start — but the beginning of a lasting partnership.

FSW weld qualification (ISO 25239:2020)

Compliant today, ready for tomorrow

At Stirtec, weld qualification is carried out in full accordance with the current FSW standard ISO 25239:2020. Our advanced in-house infrastructure enables metallographic cross-section analyses, allowing us to deliver reliable assessments of weld quality within just a few hours. Adjustments or process optimizations can therefore be implemented immediately – without long waiting times e.g. at external testing laboratories. For mechanical evaluations, our technology center is equipped with a testing machine for tensile and compression tests, as well as a workshop press for guided bend tests on welded samples, including both face and root bend tests. This setup allows us to determine fracture behavior, strength, and initial material characteristics, identify load limits, and detect potential weaknesses at an early stage.

For extended material analyses, we collaborate with accredited external partners and institutes – covering hardness measurements, pulsation and fatigue tests. Further microscopic investigations can also be conducted, such as scanning electron microscopy (SEM) combined with energy-dispersive X-ray spectroscopy (EDX), electron backscatter diffraction (EBSD), or atom probe tomography (APT). If required, X-ray or CT inspections can be performed to visualize internal structures, porosity, or defects in components non-destructively.

With this broad spectrum of testing methods, we provide you with in-depth insight into materials, components, and weld seams, which can be directly incorporated into process optimizations and series releases. Upon completion, you receive an official qualification report confirming your process reliability and compliance with the applicable standards.

A particular advantage for our customers: Stirtec actively participates in the international FSW standards committee, directly contributing to the ongoing development of FSW regulations. This insider know-how flows directly into your projects and ensures that your components and processes not only meet current requirements but also remain technologically future-proof.

pWPS-WPQR (Welding Procedure Specification-Qualification)

Qualification with certified IWE and FSW expertise

We guide you step by step through the complete weld qualification process according to the applicable FSW standard ISO 25239:2020. Starting with the preparation of the preliminary Welding Procedure Specification (pWPS), we define all relevant process parameters and materials to reliably secure subsequent series production. This is followed by the Weld Procedure Qualification Record (WPQR), during which the welding parameters are tested, optimized, and documented under realistic conditions. Finally, we create the complete qualification documentation, serving the basis for your series production approval. This ensures that your welds not only meet the quality requirements but also comply with all respective standards – for safe, reproducible, and cost-efficient production processes.

FSW prototyping & pre-serial production

Close to series from the start

In the automotive industry, most components pass through multiple development stages – from initial functional samples (A-samples) and validated prototypes (B-samples) to near-series pre-production projects (C-samples). We support our customers at every stage, provide targeted assistance with specifications, and actively contribute to the component design. It is precisely during these phases that the foundation is laid for whether a product can be produced reliably, economically, and at the desired quality in series production. Therefore, we attach great importance to realistically representing all relevant influencing factors with meaningful results, ensuring that your components are optimally prepared for series production step by step.

In our pre-series production, we handle the entire fixture construction in-house – from design and manufacturing to assembly. This end-to-end capability allows us to implement adjustments quickly and precisely, so that valuable insights feed directly into series production. At the same time, we ensure the optimal design of the FSW tools. Based on lifetime analyses and realistic trials with your original components, we can immediately implement and verify modifications. The result is tools that not only guarantee the highest process reliability but also achieve maximum service life – a decisive advantage for later series production. Additionally, we already produce in the pre-series using near-series process parameters and clamping sequences. This provides reliable information on weld quality, cycle times, and process stability during the development phase. Our infrastructure is ideally equipped for this: alongside welding, we perform all accompanying inspections and services – from milling operations and optical 3D measurements by GOM to extensive leak tests. All components work seamlessly together to form a coordinated overall package.

With Stirtec, you gain a partner who consolidates all steps and systematically supports your project from the first test part to a robust series solution.

Leak testing

Quality without compromise

Tightness determines function, safety, and efficiency. In our technology center, we test welded components using state-of-the-art methods – from overpressure, burst, or bubble tests up to 10 bar, to vacuum tests down to -1 bar, as well as precise pressure-drop tests and leak measurements with 0.001 mbar resolution. This ensures that your components meet the highest requirements – reliably, traceably, and ready for series production.

Optical part measurements

Precision in 3D by GOM

We are very proud of our ATOS GOM measurement system, which allows us to capture components and their deformation with high precision. Our trained personnel analyze each part before and after FSW, providing valuable insights into the thermomechanical effects that can occur during friction stir welding. Based on these analyses, we can optimize process parameters, detect potential distortions early, and derive appropriate corrective measures.

By default, we provide a detailed report with various views, and we customize references and measurement points according to the component’s requirements. This gives you comprehensive insights into your component behavior and enables informed process decisions. Despite GOM, we can perform in individual cases tactile measurements using our Hexagon measuring arm or, if needed, CMM measurements via external partners. This allows particularly precise geometric analyses and dimensional checks that go beyond the capabilities of optical systems.

FSW training & workshops

Know-how that creates added value

We provide hands-on expertise in friction stir welding, covering everything from the fundamentals to specific applications. In our multi-day workshops, we address key topics such as design requirements and FSW-compatible component design, the details of the FSW standard ISO 25239:2020, safe handling of typical weld defects and preventive measures, as well as relevant industrial applications. This enables your teams to build solid knowledge that can be applied directly in practice, leading to stable and efficient processes.

The workshops can be held either in our technology center or on-site at your facilities – practically oriented and tailored to your specific needs. Upon completion, each participant receives an official certificate of attendance, documenting both the successful completion of the training and the knowledge acquired.

FSW operator training & qualification

Practical & efficient

We prepare your employees for the safe and efficient operation of FSW systems. Our training programs provide not only theoretical knowledge of friction stir welding fundamentals but also emphasize hands-on experience with machines, processes and tools. The courses are conducted in accordance with ISO 25239:2020 and are precisely tailored to the specific machine type and its features. Topics include proper setup and calibration of the equipment, optimal process control, safety-relevant aspects, and quality assurance measures. Our practical operator qualification ensures that your staff build solid process expertise, enabling them to handle both routine operations and unexpected situations with confidence. This guarantees that your team is fully equipped to achieve stable, reproducible, and standards-compliant results in series production.

Upon successful completion, participants receive a certificate confirming their acquired qualification.

Ramp-Up Support

Efficient start into series production

Our ramp-up support provides on-site assistance directly at your series production lines to ensure a smooth production start. Our experts offer comprehensive consulting, troubleshooting for any challenges that arise, and targeted process and equipment optimization. This ensures that your series production runs stably, efficiently, and economically from day one, problems are resolved quickly, and your teams receive optimal support.

Our goal: maximum productivity, minimal downtime, and a fast, successful ramp-up of your production line.

24h Service-Support

Reliability around the clock

With our 24-hour service support, we are always at your side to ensure smooth operation of your FSW systems. We provide comprehensive support both online and on-site, enabling issues to be identified and resolved quickly. Through data analysis and process monitoring, we detect potential deviations or optimization opportunities early on. Fast response times ensure minimal downtime and reliable achievement of your production targets. This way, your production remains stable, efficient, and predictable – and you can always rely on our expertise.

Anwendungen für Rührreibschweißen (FSW)

Elektromobilität

Mit FSW lassen sich vielfältige Bauteile effizient und zuverlässig verbinden, darunter Batteriewannen, Statorgehäuse und Invertergehäuse für Elektrofahrzeuge.

HV-Wechselrichter-Gehäuse

Gehäuse für Elektromotoren und Getriebe

EV / PHEV Batterieträgersysteme

Mehr über Elektromobilität

Are you interested in determining the feasibility of a new concept using friction stir welding? Or do you need support in selecting the most suitable system for series production in your application?

Please contact us directly – we would be happy to advise and support you.

sales@stirtec.at

+43 316 30 98 43