Friction stir welding

Solid-state welding · High strength · Green and environmentally friendly

Introduction to Friction Stir Welding Technology

Friction Stir Welding (FSW) is an advanced solid-state joining technique invented in the UK and further developed in China. It uses a high-speed rotating tool to generate frictional heat at the joint, softening the material to a plastic state without melting. The mechanical stirring action mixes the softened materials, creating a strong metallurgical bond. This process avoids defects like porosity and hot cracking common in fusion welding, making it ideal for high-quality joining of lightweight materials such as aluminum and magnesium alloys.

Welding technology advantages

Friction stir welding offers advantages such as low heat input, minimal deformation, and absence of fusion welding defects. It enables high-strength joining without melting the material, especially for lightweight materials like aluminum and magnesium alloys. It effectively reduces energy consumption and welding residual stress, while improving joint performance and process reliability.

Some applicable materials

Material Category	Suitability	Typical Examples	Remarks
Lightweight Non-Ferrous Metals	Highly Suitable	Aluminum Alloys (e.g., 5xxx, 6xxx, 7xxx series), Magnesium Alloys, Copper Alloys	Excellent weldability, free from fusion welding defects
Dissimilar Metal Combinations	Conditionally Suitable (process optimization required)	Aluminum-Copper, Aluminum-Steel, Magnesium-Aluminum	Interface bonding control is critical
Titanium Alloys	Limited Suitability (due to high melting point)	Pure Titanium, Selected Titanium Alloys	Requires wear-resistant tools and high processing parameters
Steel	Partially Suitable (better with low-carbon steels)	Low-Carbon Steel, Stainless Steel	High melting point leads to significant tool wear
Thermoplastics	Experimental Applications	PE, PP, PVC	Low-temperature FSW processes still under development
Brittle Materials	Not Suitable	Cast Iron, High-Carbon Steel	Prone to cracking or deformation

Application Areas

Aerospace: Welding of aluminum alloy components such as aircraft fuselage and wings

Rail Transit: Manufacturing of high-speed rail and metro aluminum alloy car bodies

Automotive Industry: Battery trays for new energy vehicles and lightweight car bodies

Shipbuilding: Welding of large aluminum alloy decks and bulkheads

Electronics and Electrical Appliances: Precision heat sink and housing connections

Energy Sector: Nuclear power pipelines and renewable energy equipment

Dissimilar Materials: Specialized joints for aluminum-steel combinations

Some of our welding equipment