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Friction Stir Welding of Steel - An Industrial Reality

Webinars 12 November 2020

'Friction Stir Welding of Steel - An Industrial Reality' Webinar

Thursday 12 November 2020, 15:00-16:00 GMT

The benefits of friction stir welding (FSW), invented at TWI in 1991, have long been recognised in the fabrication of aluminium, magnesium and copper. These proven benefits; high weld strength, excellent fatigue resistance, good toughness and low distortion, have also been shown to be possible when friction stir welding steel but limitations on the longevity and reliability of the appropriate tooling for FSW of steel have so far prevented its industrial adoption in all but very niche applications.

Element Six, working in conjunction with TWI, have now developed a new tool material for FSW of steel which promises to break this impasse. This webinar will:

  • Provide details of Element Six's new tools;
  • Present data on the longevity and reliability of the tools;
  • Discuss the benefits of FSW of steel;
  • Outline potential applications for the process;
  • Provide an opportunity to question the developers.



Stephen Cater - Principal Project Leader – Friction and Forge Processes

Stephen Cater

Principal Project Leader – Friction and Forge Processes

Stephen Cater is a Principal Project Leader at TWI’s Technology Centre in Yorkshire, responsible for research into the friction stir welding (FSW) of high plasticisation point materials such as steel, titanium and nickel based alloys. A metallurgist by training, and winner of the Richard Weck Award for his work on steel, Stephen led TWI’s Core Research Programme (CRP) into the development of FSW for steel, and also led the welding elements of two recent projects looking at FSW for marine construction and repair. Stephen has published over 20 papers on FSW.

Santonu Ghosh - R&D Project Lead

Santonu Ghosh

R&D Project Lead
Element Six UK Ltd

Santonu is R&D Project Lead for strategic projects at E6’s Global Innovation Centre in Harwell, UK. For the past 7 years, he has been working as NPI lead which resulted in launching several new products and implementation of technologies related Polycrystalline Cubic Boron Nitride (PCBN) material. Santonu is responsible for developing technologies and products from TRL level 2-3 to TRL 9. He specialises in structural materials and product development. Prior to joining E6, Santonu developed a strong background in the characterisation of the microstructure and properties of ceramic and metallic materials under extreme environment. He has a PhD in Materials Engineering and a Masters in Metallurgy and published several international Journal articles and international Patents in the area of new technology and materials.  He is currently leading the initiative of developing tools for Friction Stir Welding (FSW) at Element Six.

For more information please email: