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Friction Stir Welding (FSW) Services

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Friction stir welding (FSW) is a solid-state joining process developed by Wayne Thomas at TWI Ltd in 1991. FSW works by using a wear-resistant, non-consumable tool, which is rotated and plunged into the interface of two workpieces. The welding tool is then moved through the interface where the frictional heat causes the material to heat and soften. The rotating tool then mechanically mixes the softened material to produce a solid-state bond. FSW is capable of fabricating butt or lap joints in a wide range of material thicknesses and lengths.

As a solid state processing technique, where the metals do not exceed their melting point, friction stir welded parts do not face many of the same problems associated with traditional fusion welding techniques, such as shrinkage, solidification cracking and porosity. FSW can join materials that are typically difficult to weld, including dissimilar metals and aluminium, making it a process of choice for manufacturing lightweight transport structures such as boats, trains and aeroplanes.

The process is a low-energy-input, repeatable, mechanical process capable of producing very high-strength welds in a wide range of materials, offering a potentially lower-cost, environmentally benign solution to the challenges of industry.

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Friction Stir Welding - Benefits for Industry

Advantages

Friction stir welding offers many advantages over fusion-based joining processes, especially when joining aluminium alloys:

  • A solid-state process, avoiding many of the defects associated with melting and solidification during fusion welding, such as pores and solidification cracks
  • Relatively low peak temperatures, allowing a reduction in distortion and shrinkage
  • Able to join many ‘non-weldable’ aluminium alloys; namely 2xxx and 7xxx series aluminium alloys
  • Producing superior mechanical properties
  • No filler metals, flux or shielding gas are required
  • No fumes, porosity or spatter are generated
  • Fully automated, making the process highly repeatable
  • Energy efficient
  • Does not require special edge preparation in most applications

Press Releases

Find out more about friction stir welding at TWI:

Research 1

TWI Demonstrates Breakthrough in FSW of Steel

Simultaneous double-sided friction stir welding (SDS-FSW) for steel fabrication.

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Research 2

Near Net Shape Manufacture of Titanium Alloys Using FSW

Developing friction stir welding for joining titanium alloys.

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Research 3

Friction Stir Welding of Aluminium for the Rail Industry

Delivering technical, economic and environmental benefits through FSW.

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Core Research Programme (CRP) and Joint Industry Projects (JIP)

Core Research

Each year the TWI Core Research Programme (CRP) addresses challenges on behalf of our Industrial Members as well as developing specific technologies and processes. Each of the projects under the CRP is focussed on engineering, materials or manufacturing technologies.

Find out more here

Joint Industry Projects

TWI also conducts Joint Industry Projects (JIPs) that bring together groups of Industrial Members to share the cost of research activities in areas of mutual industrial interest, gaining exclusive access to the outcomes. These projects cover a broad range of topics.

Find out more here

Friction Stir Welding at TWI

FSW was invented and pioneered by TWI Ltd. Accordingly, we have a wealth of experience of applying the process industrially, in addition to in-depth knowledge of the fundamental science that underpins it. We have also developed machines, tools and variations to the process itself, with our decades of expertise making us the go-to source of information about friction stir welding applications.

FSW is mainly used in industry to join aluminium alloys of all grades, in cast, rolled or extruded condition. Aluminium alloy butt joints with a thickness from 0.3mm to 75mm have been successfully joined in a single pass (dependent on workpiece material, machine power and structural stiffness). Other materials have also been successfully joined; namely magnesium, titanium, copper, and steel alloys. Plastics and metal matrix composites (MMC) have been explored. Dissimilar combinations between these materials have also proven possible.

Since its invention, FSW has become a proven technology in most manufacturing sectors including shipbuilding and marine, aerospace, rail, automotive, and electronics.Friction stir welding offers many advantages to the manufacturing sector for a wide range of applications. TWI has developed extensive knowledge of FSW over many years of research and development.

If you would like to know more about the process and how it can help solve your challenges, please contact us.

For more information please email:


contactus@twi.co.uk