Friction welding is a solid-state joining method that uses mechanical energy as the energy source. It uses the heat generated by the friction between the two surfaces of the welded parts to achieve metal joining. Friction welding is an effective welding method for joining aluminum and steel. However, friction welding is limited in its ability to achieve complex shaped workpiece connections, especially in the welding of dissimilar metals automotive parts such as aluminum and steel.
FSW friction stir welding overcomes this limitation. The working principle of fsw friction stir welding is that the stirring head inserts into the weld seam while rotating at high speed, and the heat generated by friction softens the material around the weld head, causing severe plastic deformation and flow. Meanwhile, the deformed metal at the weld seam is firmly bonded together through the pressure applied by the shoulder. Friction stir welding services have the advantages of low energy input, short welding time, small deformation, and relatively low welding temperature, which makes it especially suitable for welding aluminum.
Fsw friction stir welding and FSW products are widely used in industries that use aluminum. Some areas that use this welding process include:
Shipbuilding: Initially, fsw friction stir welding was used to weld hollow aluminum plates to make fishing boats. Nowadays, this welding method is common in welding aluminum refrigeration plates used for hulls and bodies of ships. Even with long weld seams, the deformation of aluminum plates is minimal because fsw friction stir welding causes the smallest deformation.
Aerospace: FSW friction stir welding is used to weld aluminum fuel tanks used to hold low-temperature oxygen in spacecraft. The cylindrical structures that make up these aluminum tanks are welded to the dome using this joining method. Additionally, fsw friction stir welding is used to join lightweight aluminum frames visible in airplane fuselages. This welding method provides a lighter option compared to riveting or bolt connections.
Train: FSW friction stir welding is the best choice for welding T-shaped stiffeners and hollow sections used in the manufacture of high-speed trains.
Friction stir welding in automotive industry: Aluminum has been identified as the best material for preparing the chassis of cars, and as such, fsw friction stir welding technology is critical in the automotive industry. Compared to fsw friction stir welding, traditional welding processes cannot produce high-tolerance parts. The fast welding time associated with this welding type makes the process more attractive compared to other welding forms.
To form the welding joint, these components work together. In terms of shape, the device is similar to a milling cutter and rotates throughout the process. It can be moved along the surface of the workpiece. Initially, the device is pushed onto the surface of the joint. Then, it is passed through the boundary of the joint by the welding device. The friction between the workpiece and the non-wearing device generates heat and raises the temperature of the metal close to the joint. At the end of the device, there is a contoured probe. Its molding method is to push the metal on both sides of the joint into each other.