RFSSW | Refill Friction Stir Spot Welding SERIES

Spot welding machinery for exceptional electric transmission

With the demanding requirements on most efficient battery systems and charging infrastructure, Stirtec presents the machine type V-RSW30 for industrial use of the innovative welding technique Refill Friction Stir Spot Welding (RFSSW). Following the advantages, the welding process is executed force-controlled under the performance of the special developed spindle system. No additional materials are required to execute the welding spot, leading to highest joint strength with exceptional mechanical and electrical properties. High currents for busbars and connector, for example, can easily be transferred to dissimilar components. The influence of coatings and remaining isolation has no impact on the quality, eliminating the need for complex and expensive cleaning processes before welding. To support electrical transmission, the welded spot area finishes with a smooth surface refilling the entrance position of the tool.

RSW40For structural and lightweight applications with highrepeatability

V-RSW30For part dimensions up to L 500 x W 500mm (option for open access without housing)

Force and position control system

Special developed RFSSW spindle for industrial use

Exceptional mechanical and electrical properties

Overview on the Refill Friction Stir Spot Welding series

RSW40

Application for spot-welding: structural and lightweight applications with high repeatability

robot-compatible for automated production

Download DatasheetRSW40

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The RSW Refill Friction Stir Spot Welding Gun is a high-performance solution for robotic, stationary and fully automated production applications. It delivers precise, reliable welds with force- or position-controlled process control and continuous monitoring of force, position and temperature.

Refill Friction Stir Spot Welding (RFSSW) creates high-strength, hole-free joints without melting the material. The solid-state process minimises heat input and distortion while providing clean weld surfaces and highly consistent, repeatable joint quality.

The RSW40 enables efficient joining of aluminium and selected dissimilar materials while reducing the need for additional joining elements.

Integrated STIRlytics® inline process monitoring continuously records relevant process forces and real-time process data. The collected data is automatically consolidated into a quality report, enabling complete 100% traceability of every weld spot.

Machine characteristics of Stirtec RSW40

use of Siemens Sinumerik One as machine control system
STIRlytics process software for 100% traceability
G-code programmable with recipe management
high repeatability and easy spot positioning
suitable for similar aluminium (Al 7XXX, Al 6XXX, Al5XXX,
Al3XXX, Al2XXX, Al1XXX) and dissimilar metals (Al-Cu, Al-
Steel, Al-composites and composites/composites)
special-developed RFSSW spindle
fexible integration into existing production systems
robot-mounted, stationary or standalone operation

For more information, please get in contact

V-RSW30

Application for spot-welding: flat busbars, electric connectors and aviation/aerospace structural parts

RFSSW machinery for dissimilar joints (aluminum-copper) and all aluminum alloys with exceptional efficiency

Download DatasheetV-RSW30

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The Stirtec V-RSW30 series provides the innovative spot-welding technology RFSSW for a wide range of serial applications in industrial use. Due to the special developed spindle system, similar-dissimilar materials are joined together with outstanding mechanical and electrical properties. The welding process is performed position/force controlled or in a combination of both control modes. The machine is capable of spot-welding solid pure aluminum to copper or electrical wiring to busbars or electric panels with a large conductor cross-section. The two variants of the refill process can be realized: pin and sleeve plunge. Including the inline process monitoring software STIRlytics®, process forces and real-life data collecting are combined into a quality report for 100% traceability.

Machine characteristics of Stirtec V-RSW30

application size up to L 300mm x W 300mm
use of Sinumerik 840D s/ machine control system
STIRlytics process software for 100% traceability
FSW force measuring system in X-, Y- and Z-direction
high repeatability and easy spot positioning
suitable for all aluminum alloys and copper applications
special-developed RFSSW spindle
short cycle timing under the use of no consumables for connecting
full protection and CE-conformity

For more information, please get in contact

Applications for the RFSSW Series

Charging Systems

RFSSW (Refill Friction Stir Spot Welding) and FSSW (Friction Stir Spot Welding) are used, among other applications, for aluminum-copper hybrid connections in electromobility. This is especially relevant when a large cross-sectional area of the joint is needed for low-resistance power transmission.

Find out more about Charging Systems

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