Advanced FSW Applications

Drawing on deep metalworking expertise to expand FSW applications

Friction Stir Welding (FSW) is a joining process that offers significant advantages over conventional arc welding methods, especially for thick aluminum structures. FSW utilizes friction between the tool and material to heat (but not melt), soften, and “stir” material across the joint to produce a solid-state weld. Concurrent Technologies Corporation (CTC) has repeatedly proven the superior performance and cost effectiveness of FSW relative to other conventional welding solutions.

What We Can Do For You

• Design for FSW Manufacturability
• Tool/Fixture Design & Fabrication
• Process Development & Optimization
• Mechanical Testing & Analysis
• Demonstration Article Fabrication
• Low Rate Initial Production
• FSW Equipment Design & Fabrication
• Implementation
• Research and technology transition to client’s product
• Qualification to AWS D1.2, D17.3 and ABS

FSW Advantages Compared to Arc Welding

• Improved mechanical properties
• For 2xxx, 5xxx & 7xxx, FSW joints have superior performance in Ultimate Tensile Strength and Elongation minimum requirements compared to traditional fusion welding
• Reduced post-weld rework and fit-up issues
• Solid-state friction stir welds have less weld distortion and build-up of residual stresses
• Enables joining of dissimilar alloys with equal/better joint properties than joints made of lesser alloy
• 5xxx to 2xxx, 5xxx to 7xxx
• Enables joining of different product forms
• Castings to forgings, forgings to plate, extrusions to plate
• Much simpler process (Computer Numerical Control [CNC]) with fewer variables to control in manufacturing
• Reduces variability or “art” inherent in traditional joining processes
• CNC speeds and feed rates
• Much higher joint quality, repeatable
• Lower training requirement for operators
• CNC operators as compared to aluminum arc welders
• Significantly higher production rates for thick materials
• 2-inch thick aluminum plate can be joined at over 2 inch/minute in a single pass
• Minimizes environment, health and safety concerns – “Green”
• Near zero dangerous fumes and emissions
• No arc or high electrical current at the weld
• No weld consumables (electrodes or gases)

FSW has made the structures of these vehicles stronger and more battlefield survivable.