Friction Stir Welding (FSW)
State-of-the-art joining process for a variety of applicationsFSW - Welding the unweldable
A wear-resistant rotating tool is plunged into the joining surface of the join partners and is subsequently traversed along the weld line. During cooling, an appropriate weld seam is produced between the respective components. The stirring process is done by a non-consumable rotating tool.
The shoulder of the tool applies force to the top of the material. The friction between the rotating shoulder of the tool and the material generates the heat input which plasticizes the material. The tool traverses the joint line, the plasticized material cools down and is forming a metallurgical joint.
Friction stir welding can be principally applied to all materials which can be plasticized. The joining process, however, is particularly suitable for welding aluminum in all alloy and manufacturing forms for thicknesses from 0.5mm up to over 50mm. Apart from that, the process enables the joining of different (dissimilar) materials. For friction stir welding of aluminum alloys, the globally valid standard DIN EN ISO 25239 – Part 1-5 can be applied.
The advantages of Friction Stir Welding
- High Joint Strength
FSW produces welds with excellent mechanical properties, due to no solidification and a forged, fine-grained microstructure. - Minimal distortion
FSW operates at lower temperatures and low heat input compared to fusion welding, welded components have a reduced distortion and residual stress levels, ideal for welded parts with tight tolerances. - Excellent fatigue behavior
FSW generates a fine-grained forged microstructure in the joint line, which lead to excellent fatigue properties. - Joining dissimilar materials
FSW can join dissimilar materials due to the low heat input high forcing action, including different aluminum alloys, like wrought aluminum to aluminum cast or aluminum to steel or copper, and even advanced composites. - Environmentally friendly
FSW produces no fumes, gases, or radiation; no protective gas, additional material or preparation of the joining edges required. - Automatization
easy to automate and monitor because it´s a mechanic mixing process.
Weldable Materials
- Aluminum in all different alloy groups
- Aluminum of different manufacturing processes (e.g.cast and wrought alloys)
- Aluminum / Copper
- Aluminum / Steel
- Aluminum / Magnesium
- Copper / Steel
- Thermoplastics
Expert perspectives on FSW processing
valuable insights on FSW processing
Applications for Friction Stir Welding (FSW)
E-Mobility
ENERGY TRANSMISSION
FOR FSW PROTOTYPE PRODUCTION AND MACHINERY
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