Friction Stir Welding – One-page (Light)
As a global leader in Production Friction Stir Welding and precision machining, Ascentec Engineering, LLC is pleased to announce we have acquired and added HFW Solutions technology to our global portfolio. As your single source supplier for Friction Stir Welding, innovative part design, prtotypign, and precision production machining needs, we are here to serve you.
What is Friction Stir Welding?
Friction stir welding (FSW) is a solid-state joining process that creates high quality, high strength welds. This produces welds of high quality in materials such as aluminum and copper.
During FSW, heat is generated by a rotating pin tool that creates a plasticized state when it is passed through the material being joined. The rotating tool creates a plasticized state so as the tool is progressed, a continuous joint is created. FSW, like other types of friction welds, is solid state in nature. As a result, friction stir welds are not susceptible to solidification related defect such as porosity or hot cracking, that may hinder fusion welding processes.
Parts can be oriented as butt welds, lap welds, and even fillet welds on highly sophisticated machines, but the most common orientation is butt welds. The rotating tool is then brought into contact with the work pieces. The tool has two basic components: the pin tool, which protrudes from the lower surface of the tool, and the shoulder, which is relatively large diameter. The length of the pin tool is directly correlated to the thickness of the work pieces.
Welding is initiated by first plunging the rotating pin tool into the work pieces until the shoulder is in close contact with the components top surface. Friction heat is generated as the rotating shoulder rubs on the top surface under an applied force. Once sufficient heat is generated and conducted into the work piece, the rotating tool is propelled forward. Material is softened by the heating action of the shoulder, and transported by the pin tool across the bondline, facilitating the joint. Friction stir welding is fast becoming the process of choice for welding.
- Joins Wide Variety of Materials
- High Strength Joints/High Toughness
- Localized Processing Capabilities
- Low Heat Input/Low Distortion
- Part Accessibility is Required
- Process Forces Require Ample Fixturing
- Localized Material Temper Disruption
Process for Square Butt Weld
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Equipment for Friction Stir Welding
Friction Stir Welding Machine
This is the most important piece of equipment used in friction stir welding. It consists of a rotating spindle that holds the tool, a motor that drives the spindle, and a mechanism for applying force to the tool. The machine is designed to provide precise control over the speed, rotation, and axial force applied to the tool.
Friction Stir Welding Pin Tool
This is the tool that is used to generate the heat and plastic deformation necessary for welding. The tool consists of a shoulder and a pin, both of which are made from a high-strength, wear-resistant material such as tool steel.
Workholding Fixtures
Friction stir welding requires the material being welded to be held in place, usually with the use of workholding fixtures. These fixtures can range from simple clamps to more complex, custom-made setups that are designed to accommodate the specific geometry of the part being welded.
One of the key advantages of FSW is that it can be performed using customized computer numerical control (CNC) machines. When using a CNC machine for FSW, the machine is programmed with the desired welding parameters, such as tool rotation speed, travel speed, and vertical axial load. This allows for a high level of repeatability and consistency. CNC machines can be programmed to perform the same welding process multiple times, ensuring that the final product is of consistent quality. Additionally, CNC machines can be programmed to adjust the welding parameters in real-time based on feedback, allowing for consistent welding performance.
Design for Manufacturability (DFM) in Friction Stir Welding:
7 Essential Principles for Efficiency and Quality
Design Simplicity
Standardization
Design for weld assembly, fixturing and welding constraint
Minimize Material Waste
Design for Testability
Design for Robustness
Design for Cost
White Papers
Effect of Fit-Up Tolerances on the Strength of Friction Stir Welds
Part fit-up variations are critical to the joint quality produced by joining operations like friction stir welding (FSW). Typical fit-up issues may include: gaps, misalignment between the weld path and joint line, setup related variations, voids or holes in the weld path, mismatch between materials being joined, etc. These and other factors potentially result in variations in mechanical properties between the start and finish of the weld as well as lead to the possible formation of defects along the joint line. The purpose of this study was to determine the robustness of the friction stir welding process to selected imperfections in joint fit-up between plates in butt-welding. Specifically, it includes a study of the effect of part fit-up variations on the transverse joint tensile strength of 0.125” thick friction stir butt-welded 7075-T73 aluminum plate. Welds were performed on an MTS® ISTIR™ PDS friction stir weld machine at the National Institute for Aviation Research in Wichita, KS. It was found that the FSW process was capable of creating a sound defect-free joint for a range of typical fit-up discontinuities. The tolerance zone for weld path misalignment to the joint line was related to the formation of fine nugget grain structure at the bottom of the weld, with two- thirds of the tolerance zone located on the advancing side of the pin. It was also determined that a certain amount of plate gap or voids in the weld path can be tolerated without a decrease in tensile strength; beyond that point, volumetric defects form in the nugget. Otherwise, there is little variation in tensile properties along the weld joint when care is taken to ensure gap and alignment tolerances are not exceeded.
Material Compatibilities
Aluminum
Aluminum is one of the most common metals to friction stir weld because it has low weight, good corrosion resistance, and is easily welded. When aluminum is combined with alloying elements it can produce a range of useful mechanical properties.
1XXX aluminum alloy is almost pure aluminum and has low mechanical strength, high ductility, excellent corrosion resistance and high electrical conductivity. While fusion welding works for aluminum alloys, friction stir welding is a much better alternative.
2XXX aluminum alloy is composed of aluminum and copper. This alloy is useful in high-strength sheet or plate aerospace applications. It is extremely sensitive to hot cracking, and therefore un-weldable by fusion techniques. However, it is readily weldable using friction stir welding.
3XXX aluminum alloy is made up of aluminum and manganese. This alloy is a medium-strength aluminum alloy. It is very formable and often used for heat exchangers and air conditioners. Alloys of this series have moderate mechanical strength, high ductility and excellent corrosion resistance. The 3XXX aluminum alloy is easily friction stir weldable.
4XXX aluminum alloy is composed of aluminum and silicon. The 4XXX series alloys are most often encountered when they are being used as filler material within the welding or brazing processes, however this alloy is still able to be friction stir welded.
5XXX aluminum alloy is made of aluminum and magnesium. This alloy is used for high-strength sheet and plate alloys in marine applications, and is especially useful for building ships. 5XXX series alloys have excellent fusion weldability, but using fusions welding creates a large reduction in strength so a thicker material is needed to get the same strength. The friction stir welding process does not reduce strength and is a more cost effective solid state joining solution.
6XXX aluminum alloy is composed of aluminum, magnesium, and silicon. This alloy is useful for extrusions, large sheets, and plates. 6000 series aluminum alloys can be tricky to weld because they are prone to cracking, but with friction stir welding this issue does not exist, and they are readily weldable.
7XXX aluminum alloys are made of aluminum and zinc. This is especially useful for high-strength aerospace applications. These alloys are mostly unweldable due to their susceptibility to hot-cracking and stress-corrosion but are easily weldable using friction stir welding.
Copper
The high thermal and electrical conductivity of copper have made it a difficult material to weld in the past, particularly in thick sections. As FSW does not melt the material and applies mechanically generated heating locally, it has been a useful process for welding copper.
Applications in copper alloys include the welding of copper cold plates and heat sinks and the fabrication of brass and bronze components, including propellers and impellers, for marine applications. Brass can also be friction stir welded and used in other architectural applications.
Dissimilar Materials
As FSW is a solid-state process that mechanically stirs metals together to form a bond between them, it can be used to join dissimilar metals. This is most easily achieved when the metals to be joined have similar thermal properties and melting temperatures. While fusion welding does not allow for dissimilar alloys or metals to be welded together, dissimilar alloys such as 2xxx and 7xxx aluminum alloys can be welded together using friction stir welding.
Using friction stir welding, dissimilar metals can also be joined together such as aluminum and copper. This is especially useful in the automotive and electrical industries. Dissimilar metal welding finds great use for applications such as the manufacturing of batteries, fine wires, fuel cells and even medical devices. Dissimilar metal welding is also great for other applications in the aerospace and thermal management industries as well.
SERVICES
A smarter way to do things…
We do things smarter and faster to ensure our customers needs are met. Ascentec Engineering uses a process-driven, methodical, repeatable approach to developing production, engineering and quality excellence.
Friction Stir Welding
Friction stir welding is a game-changing technology and is regarded as the best joining method for aluminum. A solid-state joining process that uses frictional heat, friction stir welding creates a high-strength. From concept, design, and into volume production, we can assist you in all stages of your project becoming your all-around engineering, materials and fabrication resource to provide first-class quality solutions.
Machining
Ascentec Engineering team members specialize in developing and producing high-volume production friction stir welded, machined, and fabricated products in virtually every alloy and joint group for our partners. Friction stir welding paired with integrated machining services and precision assembly and coatings allows Ascentec Engineering to be a market leader in manufacturing high end fabricated structures. We have manufacturing solutions for many industries, including: semiconductor, aerospace, hybrid electric vehicle, and thermal.
CNC Machining
We believe exceptional CNC machining starts with a full understanding of the customer’s needs. Our process starts with a thorough design and certified quality material. Our fully automated CNC machines and handling systems allow us to create quality precision custom products.
Engineering Services
By partnering with our customers, together we create unprecedented outcomes developing better ideas. We apply our vast engineering and business knowledge to build practical solutions that are safe, innovative, and sustainable. Ascentec Engineering team members have developed production friction stir welds in virtually every alloy and joint group for customers in:
- Semiconductor
- Spaceflight
- Aerospace
- Agricultural/heavy equipment
- Automotive
- Thermal Management
Ascentec Engineering is a leader in friction stir welding engineering, providing research and consultancy to our clients.
We work together with our clients to help solve manufacturing problems and achieve production goals. We provide them with complete access to our engineering expertise, and consult with them from day one through the production of parts.
We listen closely to concerns. This allows us to design and manufacture the correct tooling to quickly and properly friction stir weld parts.
Innovative solutions have been the engine that drives Ascentec Engineering to achieve extraordinary success in solving our customers’ most difficult manufacturing problems.
Design For Manufacturing
At Ascentec Engineering our engineering team is with our clients from the beginning of the project to testing the products. They provide the following services and more:
- Ensures clients maximize Ascentec Engineering ‘s unique capabilities such as FSW complex, aluminum structures
- Product Requirements
- Material
- Dimensions, tolerances, preparation, properties
- Process
- Material input/output, throughput, process timeline, tooling, material handling
Click here for an expanded discussion of Design for Manufacturability in Friction Stir Welding.
- Process development to define material properties (if needed)
- Initial design and trade off analysis per FRS
- Evaluate tooling (lowest risk, highest rigidity, minimize distortion)
- Evaluate products at the component, sub- assembly, and structural module level
- Integration strategy to streamline products into manufacturing facility
- Reduce scrap, labor, and time
Manufacturing Solutions
Friction stir welding paired with integrated machining services and precision assembly and coatings allows Ascentec Engineering to be a market leader in manufacturing high end fabricated structures. We have manufacturing solutions for many industries, including:
Aerospace and Spaceflight
Ascentec Engineering is a trusted leader in precision manufacturing, product development and custom assemblies for the aerospace industry. Our experience makes us a leading provider of aircraft parts, metal fabrication, and quality machined components.
Semiconductor
Ascentec Engineering is an Industry leader with products used throughout the most advanced semiconductor processing tools. Our services enable wafer handling and processing at extreme cleanliness and high vacuum
Hybrid Electric Vehicle
Ascentec Engineering is an industry leader in providing permanently sealed liquid cooled inverter units and electronic enclosures. The elimination of gaskets not only eliminates leaks it allows for a lower cost part. Using friction stir welding in our manufacturing process allows us to create products with reduced weight, lower cost, and a high degree of customization.
Thermal
For custom thermal management solution design, development and manufacturing Ascentec Engineering provides innovative solutions. We are a leading manufacturer of hermetically sealed cold plates and heat sinks for spaceflight, aerospace, aviation, agriculture machinery and the automotive industries.
Other Manufacturing Solutions
Energy
Inverter Housing & Components Products | Cold Plates | Thinned Heatsinks | Solar Module Frames
Industries
Semiconductor
Semiconductor manufacturing is a core industry of focus for Ascentec. We pride ourselves in our ability to deliver on complex machining projects, with extremely high quality scores. Our 5-axis machines are perfectly suited to the latest designs found in advanced semiconductor processing equipment. Rapid turn times are commonplace for our Rapid Prototype Machining cell. This cell is an autonomous group that can react instantly to changes in requirements and schedule needs. The key to the rapid turn times we enjoy lies in the very skilled operators we have in our production group. They are capable of programming, setting up, running and evaluating the quality of the articles they produce. This streamlines the production process. Contact Ascentec today if you need complex work completed on a short schedule.
Aerospace, Spaceflight, and Aviation
Spaceflight environments demand the most exacting assembly processes, materials and controls. Ascentec provides complete sourcing, machining, and hardware assembly services.
Spaceflight manufacturing requires the most exacting standards and controls. Ascentec manufactures some of the most advanced hardware used in launch systems, as well as satelites. We specialize in machining complex hardware with tight tolerances. We offer complete assembly services as well. Our engineering department provides comprehensive design for manufacturability reviews, which have proven to dramatically cut lead time and cost. Involving Ascentec throughout the design cycle results in excellent quality product and clear achievement of the design intent. Contact Ascentec today for your spaceflight hardware needs.
Ascentec Engineering is a trusted leader in precision manufacturing, product development and custom assemblies for the aerospace industry. Our experience makes us a leading provider of aircraft parts, metal fabrication, and quality machined components. Ascentec Engineering has friction stir welding and manufacturing capabilities for many products in the aerospace industry.
INDUSTRY PRODUCTS
Most aerospace applications are still being tested, as it is a relatively new field for frictions stir welding. There are many opportunities to weld several parts for both civilian and military aircraft. Using friction stir welding will significantly reduce cost and weight.
Ascentec Engineering supports many applications.
ADVANTAGE
- Lower production times resulting in superior quality delivered in a fraction of the time
- Significantly reduces end-weight
- Environmentally friendly
- Improved weld strength
Applications
In recent years, friction stir welding (FSW), an environmentally lean manufacturing process, has become increasingly popular in aerospace manufacturing. Some advantages of friction stir welding are reduced end weight, faster time on production, no heat distortion, superior weld quality and it is environmentally sound. This solid state joining process produces no fumes, uses no gas or filler wire, and the weight saved reduces fuel use.
FSW was adapted for joining fuel tanks on satellite launch vehicles in the late 1990’s. There was improved efficiency, strength, reduced rework, and a substantial cost reduction. Friction stir welding in commercial aircraft manufacturing has developed at a much slower pace. However, due to weight changes and cost savings, its popularity has seen a dramatic increase. Weight is one of the biggest challenges for aircraft manufacturers. By joining aluminum alloy stringers to skins for aircraft wings and fuselage structures using friction stir welding allows for thousands of rivets to be removed, which will significantly reduce weight.
Ascentec Engineering offers many manufacturing solutions for aerospace.
Hybrid Electric Vehicle
Ascentec Engineering is an industry leader in providing permanently sealed liquid cooled inverter units and electronic enclosures. The elimination of gaskets not only eliminates leaks it allows for a lower cost part. Using friction stir welding in our manufacturing process allows us to create products with reduced weight, lower cost, and a high degree of customization.
Ascentec Engineering has friction stir welding and manufacturing capabilities for many products in the Hybrid Electric Vehicle industry such as:
Cold Plates | Inverters | Electronic Enclosures | Venturi | Fuel Tanks | Battery Trays | Mounting Brackets | Frames
Why Ascentec Engineering
Ascentec Engineering is an industry leader in providing permanently sealed liquid cooled inverter units and electronic enclosures. The elimination of gaskets not only eliminates leaks it allows for a lower cost part. Ascentec Engineering has the ability to produce:
- Cold Plates | Inverters
Hermetic Enclosures
- Electronic Enclosures | Venturi | Fuel Tanks
Automotive Components
- Battery Trays | Mounting Brackets | Frames
Benefits of Friction Stir Welding
- Reduce weight
- Lower cost
- High degree of customization
- Environmentally friendly
- Spot weld thin aluminum sheets
- No filler material
- Deformations less likely
- Aesthetically appealing
Applications
Aluminum is corrosion resistant, strong, and has a low mass. Friction stir welding contributes to an improvement in fuel economy by reducing body weight substantially. To make a door frame, hoods, and other auto parts, sheets of metal are welded together, then cut into appropriate sizes, and finally stamped into the final shape.
Using friction stir welding allows a high degree of customization. For example, a thicker gauge metal can be used on one side of a car where extra strength is needed. That part can be joined to a thinner gauge metal on the side of the car where extra strength isn’t needed. The elimination of gaskets not only eliminates leaks it allows for a lower cost part. Ascentec Engineering is an industry leader in providing permanently sealed liquid cooled inverter units and electronic enclosures.
Thermal
For custom thermal management solution design, development and manufacturing Ascentec Engineering provides innovative solutions. We are a leading manufacturer of hermetically sealed cold plates and heat sinks.
INDUSTRY PRODUCTS
Ascentec Engineering has become the expert in friction stir welding high conductivity cold plates into all types of machined, extruded and cast aluminum alloys. At Ascentec Engineering we have lower production times which results in superior quality delivered in a fraction of the time. Ascentec Engineering has the ability to produce:
Thermal Management Systems
- Cold Plates | Heat Sinks
ADVANTAGE
- Lower production times
- High degree of customization
- Significantly reduces end-weight
- Improved weld strength
- No filler material
- Deformations less likely
- Environmentally friendly
Applications
Ascentec Engineering designs and manufactures the best performing and most cost effective cold plates for liquid cooling available today. Ascentec Engineering is an industry leader in the thermal industry. We offer a myriad of fin and custom pin fin geometries, designed to improve reliability and thermal efficiency in cooling electronic systems. Our thermal products feature friction stir welded and CNC fabricated construction. This creates a leak proof seal that is stronger and more reliable than any other cold plate joining method. Ascentec Engineering can guarantee that our thermal solutions are leak free, stronger, and more durable.
Products
Semiconductor
Semiconductor manufacturing is a core industry of focus for Ascentec. We pride ourselves in our ability to deliver on complex machining projects, with extremely high quality scores. Our 5-axis machines are perfectly suited to the latest designs found in advanced semiconductor processing equipment. Rapid turn times are commonplace for our Rapid Prototype Machining cell. This cell is an autonomous group that can react instantly to changes in requirements and schedule needs. The key to the rapid turn times we enjoy lies in the very skilled operators we have in our production group. They are capable of programming, setting up, running and evaluating the quality of the articles they produce. This streamlines the production process. Contact Ascentec today if you need complex work completed on a short schedule.
Friction Stir Welding Solutions for the Aerospace Industry
Ascentec Engineering has worked with Aerospace industry organizations to develop and create new and innovative products and solutions that are stronger, lighter, resistant to higher temperatures, and more reliable. We understand the complexities of planning for the inevitable change within the Aerospace industry and the critical need for solutions that can adapt over time.
Making a Difference in Aerospace Manufacturing
Ascentec Engineering ‘s friction stir welding machine is highly sophisticated. Our process knowledge allows for highly repeatable welds. Components are welded together utilizing friction stir welding to produce “near net shape” assemblies requiring minimal additional machining, saving costly time and material costs.
Ascentec Engineering is continually improving efficiency and strength with versatile and unique materials. When we make a new weld, we push the boundaries of where and how our machines can operate. This is just another example of the Ascentec Engineering way of thinking.
Why Friction Stir Welding is Vital for Aerospace Applications
The demand for larger and more fuel-efficient aircraft means that aero-engines are growing in thrust, temperature, and size. Withstanding the higher temperatures requires critical aircraft and aerospace components made with unique materials. While these materials can be difficult and many times impossible to weld with conventional methods, they can be joined with the friction stir welding process.
The Friction Stir Welding Process for the Aerospace Industry can be Utilized for:
- Military and scientific applications
- Repair of faulty welds
Applications
In recent years, friction stir welding (FSW), an environmentally lean manufacturing process, has become increasingly popular in aerospace manufacturing. Some advantages of friction stir welding are reduced end weight, faster time on production, no heat distortion, superior weld quality and it is environmentally sound. This solid state joining process produces no fumes, uses no gas or filler wire, and the weight saved reduces fuel use.
FSW was adapted for joining fuel tanks on satellite launch vehicles in the late 1990’s. There was improved efficiency, strength, reduced rework, and a substantial cost reduction. Friction stir welding in commercial aircraft manufacturing has developed at a much slower pace. However, due to weight changes and cost savings, its popularity has seen a dramatic increase. Weight is one of the biggest challenges for aircraft manufacturers. By joining aluminum alloy stringers to skins for aircraft wings and fuselage structures using friction stir welding allows for thousands of rivets to be removed, which will significantly reduce weight.
Ascentec Engineering offers many manufacturing solutions for aerospace.
Hybrid Electric Vehicle Products
Friction Stir Welding and machining Solutions for the Automotive Industry
Our extensive experience with automotive welding solutions is evident in the enormous variety of parts our machines produce. Those applications include battery trays, crush cans, electronic enclosures, cold plates, and many more. Friction stir welding and machining may be fully integrated into automated production lines to handle this industry’s high volume demands.
How is Ascentec Engineering, LLC Solving Current Problems in the Automotive Manufacturing Industry
In recent years, the automotive industry has faced an increasing number of challenges. Customers in the automotive industry demanded a machine that could keep product costs low, meet rigorous standards, and keep up with changing trends. Tier 1 and Tier 2 automotive suppliers look for a solutions that will stand up to harsh environments but also help them achieve their lean manufacturing goals. Ascentec Engineering is able to meet their needs with our high quality solutions.
Why friction stir welding is vital for hybrid electric vehicle applications
Friction Stir Welding is used across the automotive industry, utilized in creating large profiles, tailor welded blanks, and other high strength material applications such as crush cans and battery trays. Friction stir welding allows for the joining of smaller extrusions to make larger profiles. Larger profiles could be fabricated but can become very expensive. Friction stir welding provides a cost effective option for these large parts while holding tight tolerances and creating a very strong joint.
Friction stir welding also enables the joining of low weight, high strength materials that are difficult to weld with traditional methods. Many of these Friction Stir Welded parts require some final machining steps before they are ready to be put into assembly. Ascentec Engineering’s unparalleled CNC machining capabilities allow for final machining to be completed in house.
The Friction Stir Welding Process for the Hybrid Electric Vehicle Industry can be Utilized for:
- Battery Trays
- Electronic Enclosures
- Exhaust Gas and Re-circulation (EGR) Units
- Liquid Cold Plates
- Inverter Housings
- Mounting Brackets
Friction Stir Welding of Power Electronics Cold Plates
Friction Stir Welding (FSW) is a solid-state welding process that has been gaining popularity in recent years due to its ability to join dissimilar materials with minimal distortion and high strength. One area where FSW is particularly well-suited is the fabrication of cold plates for power electronics.
A cold plate is a key component in power electronics systems, as it is responsible for removing heat generated by the electronic devices and dissipating it into the surrounding environment. Cold plates typically consist of a base plate made of a thermally conductive material, such as copper or aluminum, and one or more layers of thermal interface material (TIM) that improve the thermal contact between the electronic devices and the base plate. The base plate and TIM layers are typically joined together using brazing or soldering, but these processes have several limitations when it comes to power electronics applications. Brazing and soldering can introduce impurities into the base plate, which can negatively impact the performance of the electronic devices. Furthermore, these processes can cause significant distortion in the base plate, which can make it difficult to achieve good thermal contact between the electronic devices and the base plate.
FSW, on the other hand, offers several advantages over brazing and soldering for joining cold plates. FSW is a solid-state process, which means that it does not introduce any impurities into the base plate. Additionally, FSW can be used to join dissimilar materials, such as aluminum and copper, which is not possible with brazing or soldering. Furthermore, FSW can be used to join thick materials, such as those used in power electronics cold plates, without causing significant distortion.
The FSW process begins by inserting a rotating tool into the adjacent region of the two parts to be joined. The tool is then moved along the joint while applying a downward force, which causes the material to flow and be joined together. The tool also stirs the material, which helps to create a homogeneous microstructure in the welded region.
One of the key challenges in using FSW for cold plates is ensuring good thermal contact between the electronic devices and the base plate. This can be achieved by carefully controlling the process parameters, such as the rotation speed of the tool and the welding speed, to minimize the amount of distortion in the base plate. Careful design of the manufacturing sequence for associated processes such as CNC machining, assembly and coating is also key to successful implementation of FSW in cold plate products.
In conclusion, FSW is a proven technique for joining cold plates for power electronics. Its ability to join dissimilar materials with minimal distortion, high strength and no impurities makes it a great alternative to traditional methods like brazing and soldering for power electronics applications.
Friction Stir Welding of Aluminum Tailor Welded Blanks
Friction stir welding (FSW) is a solid-state welding process that can be utilized in the automotive industry for manufacturing tailor welded blanks (TWBs) in aluminum alloys. TWBs are made by joining two or more sheets of metal together, each with different thicknesses or compositions, to produce a single sheet of material with varying properties.
The resulting TWB sheet metal component has distinct areas that have been tailored to have different material properties, thicknesses, or coatings, depending on the specific application. This can provide a range of benefits, including:
- Weight reduction: By using different grades of aluminum with varying thicknesses, a TWB can be designed to be both lighter and stronger than a single sheet of uniform material.
- Cost reduction: TWBs can be made from lower-cost materials by using higher-grade materials only where they are needed. This can result in significant cost savings without sacrificing performance.
- Improved functionality: TWBs can be designed to have specific material properties in different areas of the component, such as increased strength, improved formability or better corrosion resistance, to improve overall functionality.
Friction stir welding can be employed to join the individual aluminum sheets together in one pass, creating a strong and continuous bond while avoiding the introduction of defects or weaknesses. FSW is also useful for joining dissimilar alloys or thicknesses, which may be difficult to join with conventional welding methods.
The use of friction stir welding to create TWBs provides greater control over the material properties of automotive components. FSW allows for more precise tailoring of material properties to meet the specific requirements of the application. Moreover, the FSW process can be utilized to refine the material properties of the TWB by inducing plastic deformation and grain refinement in the weld zone, resulting in improved strength and ductility of the TWB.
Overall, friction stir welding is an effective tool for the manufacturing of TWBs in the automotive industry, as it facilitates the creation of lightweight, robust, and cost-effective components that can be tailored to specific requirements.
The resulting TWB sheet metal component has distinct areas that have been tailored to have different material properties, thicknesses, or coatings, depending on the specific application. This can provide a range of benefits, including:
1. Weight reduction: By using different grades of aluminum with varying thicknesses, a TWB can be designed to be both lighter and stronger than a single sheet of uniform material.
2. Cost reduction: TWBs can be made from lower-cost materials by using higher-grade materials only where they are needed. This can result in significant cost savings without sacrificing performance.
3. Improved functionality: TWBs can be designed to have specific material properties in different areas of the component, such as increased strength, improved formability or better corrosion resistance, to improve overall functionality.
Friction stir welding can be employed to join the individual aluminum sheets together in one pass, creating a strong and continuous bond while avoiding the introduction of defects or weaknesses. FSW is also useful for joining dissimilar alloys or thicknesses, which may be difficult to join with conventional welding methods.
The use of friction stir welding to create TWBs provides greater control over the material properties of automotive components. FSW allows for more precise tailoring of material properties to meet the specific requirements of the application. Moreover, the FSW process can be utilized to refine the material properties of the TWB by inducing plastic deformation and grain refinement in the weld zone, resulting in improved strength and ductility of the TWB.
Overall, friction stir welding is an effective tool for the manufacturing of TWBs in the automotive industry, as it facilitates the creation of lightweight, robust, and cost-effective components that can be tailored to specific requirements.
Friction Stir Welding Solutions for the Thermal Industry
Ascentec Engineering has worked with thermal industry companies to develop and create new and innovative parts and solutions that are stronger, lighter, hermetically sealed, and more reliable. Our thermal industries solutions include making our products from extrusions or castings. We understand the complexities of planning for the inevitable change within the thermal industry and the critical need for solutions that can adapt over time.
Making a Difference in Thermal Manufacturing
Our extensive experience in thermal friction stir welding solutions is evident in the enormous variety of parts our machines produce. Those applications include all types of custom heat sinks and cold plates. Friction stir welding plays an enormous role in thermal industry products. Friction stir welding machines produce reliable and consistent results in cold plates and heat sinks. Friction stir welding thermal products is more reliable than traditional methods. No leaking, improving aesthetics, providing strength, delivering cost savings – these are just a few of the many benefits friction welding produces in the thermal industry.
Why Friction Stir Welding is Vital for Thermal Applications
Friction Stir Welding not only adds new, improved weld strength and durability to thermal products but can significantly improve the product’s aesthetic quality while eliminating material and processing steps associated with arc based methods of welding. Friction stir welding tooling and techniques allow for the assembly of a complete product component at one time, and in just seconds, while generating minimal heat and few external areas to “clean up” machine to near net shape. Friction stir welding for the thermal industry allows us to make 100% leak free parts. Machining thermal products allows us to produce highly complex parts. Final products can use a minimalist design approach, coupled with a secure, durable, tamper resistant enclosure.
Hermetically seal cold plate type products and join smaller, air cooled heat sinks together to produce a larger finished product. Ascentec Engineering can friction stir weld and manufacture:
- Cold Plates
- Heat Sinks
Aluminum FSW Casting to Extrusion
The Benefits of Using Friction Stir Welding for Cold Plate Assembly with Dissimilar Materials
Friction stir welding (FSW) is a solid-state joining process that can be used to weld dissimilar materials with different properties. In the case of manufacturing liquid cold plates, using a variety of materials in different parts of the welded assembly can have several potential advantages, including:
- Enhanced heat transfer: Different materials have different thermal properties, such as thermal conductivity and specific heat capacity. By using materials with high thermal conductivity in the areas where heat transfer is most critical, such as the cooling channels, and materials with lower thermal conductivity in areas where thermal insulation is desirable, such as the outer casing, it may be possible to enhance overall heat transfer performance of the liquid cold plate.
- Improved mechanical properties: Different materials have different mechanical properties, such as strength and ductility. By selecting materials with appropriate mechanical properties for different parts of the liquid cold plate, it may be possible to improve overall mechanical performance, such as resistance to vibration and fatigue.
- Cost savings: Using a variety of materials in the liquid cold plate can allow for more efficient use of materials, potentially resulting in cost savings. For example, high-performance materials can be used in critical areas, while lower-cost materials can be used in less critical areas. In addition, using castings, plate and extrusion alloys in targeted locations can optimize the cost depending on the requirements and quantity of the parts needed.
- Customization: By using a variety of materials, it may be possible to customize the liquid cold plate to meet specific design requirements, such as weight reduction or corrosion resistance. This can result in a more optimized design and improved performance.
Overall, using a variety of materials in different parts of a friction stir welded liquid cold plate assembly can offer potential advantages in terms of enhanced heat transfer, improved mechanical properties, cost savings, and customization. However, careful consideration must be given to material selection and welding parameters to ensure that the different materials can be effectively joined together using FSW.
FAQ
What is Friction Stir Welding?
Friction stir welding is a solid-state joining process that uses frictional heat. Using this method creates a high-strength, high-quality weld. Visit our friction stir welding page to learn more.
Who invented friction stir welding?
Friction Stir Welding (FSW) was invented in 1991, by Wayne Thomas, at The Welding Institute (TWI). This process overcomes many of the problems associated with traditional joining techniques.
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What materials can be friction stir welded?
Initially friction stir welding was confined to relatively soft materials such as lead, zinc, magnesium and a range of aluminum alloys. More recently, copper, titanium, low carbon ferritic steel, alloy steels, stainless steels and nickel alloys have been welded. In theory, any material which can be hot worked should be weldable by this process. However, the pin tool material is often the limiting factor, rather than the material being welded. Visit our materials compatibility page to learn which materials can be welded together.
How does friction stir welding compare with other processes with respect to cost?
Friction stir welding of aluminium alloys has been cited by many users as a cost-saving process. This is in part due to the elimination of consumable costs, but is also due to the ability to make most welds in one or two passes, even in thick material. FSW is also an efficient process in terms of energy consumption, which can also lead to significant cost savings. The fully automated nature of the process also reduces labor costs and the possibility of defects. Visit our friction stir welding page to learn more.
What are the advantages of friction welding?
There are many advantages with this joining process including the absence of toxic fumes or splatter, no consumables are required to produce the weld, and it is a process that can be easily automated which makes it perfect for industrial use. Problems such as, solidification cracking, porosity, solute redistribution are not a problem when friction stir welding is used. There are fewer defects when using friction stir welding. This process is also a better welding process for the environment. Visit our friction stir welding page to learn more.
What are some common applications for friction stir welding?
Friction stir welding has been widely adopted in many branches of manufacturing and engineering. HFW Solutions provides this technology for many industries including aerospace, hybrid electric vehicle, marine, rail, thermal, and many more. See what industries we serve and products we can make.
Why is friction stir welding used?
Friction stir welding is primarily used on extruded aluminum and particularly for structures which need very high weld strength. FSW is also found in modern shipbuilding, trains, hybrid electric vehicle, and aerospace applications. Visit our friction stir welding page to learn more.
What is meant by friction stir processing?
Friction stir processing (FSP) is a method of changing the properties of a metal through intense, localized plastic deformation. This deformation is produced by forcibly inserting a non-consumable tool into the material, and revolving the tool in a stirring motion as it is pushed laterally through the material. This type of processing gives superior strength and formability to the product. Visit our friction stir welding page to learn more.
About
Ascentec Engineering Friction Stir Welding Capabilities
We have over 20 years experience welding parts across many different industries including semiconductor, aerospace, electric and hybrid electric vehicles, agriculture equipment, and thermal management. Ascentec Engineering is the premier friction stir welding service provider in North America. Our machines are state of the art and our weld engineers are experts in their craft.
Superior Mechanical Characteristics
Joining Dissimilar Materials