Mon, 20 April, 2026
Our experts at TWI have successfully completed a 2D corner weld using robotic friction stir welding (FSW), marking another important step forward in advanced aerospace manufacturing.
Delivered as part of the ATI-funded MASTER project (Metallic Aerospace Structures Technologies for Eco-Social Returns), this breakthrough supports the development of safe, lightweight and efficient hydrogen-powered flight.
At the heart of the challenge is the need for advanced liquid hydrogen fuel storage systems, which depend on high-strength, high-integrity joints for mission-critical aerospace structures.
Invented at TWI in 1991, FSW continues to evolve through decades of innovation and in-house expertise. By combining our deep capabilities in joining technology, advanced materials and hydrogen systems, the MASTER project has already achieved the successful production of a hydrogen storage tank demonstrator.
Now, with this latest advancement in 2D corner welding, we have demonstrated how robotic FSW can be used to weld internal features within liquid hydrogen storage tanks, opening up exciting new possibilities for future aircraft design.
This milestone was achieved using a 6-axis KUKA KR500 robot at the TWI Technology Centre Yorkshire, integrated with a dedicated KUKA FSW head. The system enables complex weld paths with exceptional precision, further showcasing the flexibility of this recently installed robotic platform.
Watch the 2D corner welding process in action below
See the latest developments live at IFWC 2026
Our newest breakthroughs in fabrication and demonstrator development will be presented at the upcoming International Friction Welding Conference 2026, hosted at our Cambridge headquarters from 19–21 May 2026.
This newly combined global event brings together the 14th International Symposium on Friction Stir Welding and the 6th International Symposium on Linear Friction Welding, creating a must-attend forum for researchers, engineers and industry leaders across friction joining technologies.
Learn more and register: https://www.ifwconference.com/
To explore how our FSW expertise can support your next project, contact contactus@twi.co.uk