FSW Stirweld tools are robust and powerful at a controlled cost.
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For the FSW, the quality of the weld depends on the geometry and the quality of the tool.
General characteristics of our FSW tools
Our goal is to provide the solution for every type of parts and materials.
The right tool choice has a direct impact on the wear and quality of the weld. Thanks to the FSW experience of its team, StirWeld offers you the most suitable tool for your use by combining quality, price and reliability.
- FSW Tools Structure
The FSW tool consists of a shoulder to warm the material by friction and a pawn to stir the components. These two parts are essential elements to guarantee the good mixing of the material and the seamless welding.
- The shoulder is placed on the surface of the parts to be welded.
Thus, it rubs on the material and creates the necessary friction heat to "soften" the pieces (about 400 ° C aluminum). The metallurgical phenomenon is close to that of extrusion. In addition, because of its shape and size, the shoulder confines the material and prevents it from leaving the kneaded area.
- The pawn enters the parts to be welded.
Thanks to its shape, it will both heat the material by shearing effect and ensure the mixing of the material despite the presence of aluminum oxide on the parts. Thus, the choice of a tool adapted to the materials to be welded associated with qualified welding parameters will allow the material to close behind the passage of the tool, to crush the aluminum oxide and to obtain a irreproachable welding.
The strong stirring of the material by the pion and the heat generated by the shoulder cause a phenomenon of recrystallization of the aluminum. This results in the precipitation of fine grains that will contribute to the very good mechanical strength of FSW welds.
Our tools can weld all part configurations:
- Butt (similar or dissimilar thicknesses)
- T-shaped (or welded at an internal angle through the top)
Life of our tools: proven endurance
FSW tools are solicited in two ways:
- Cyclic fatigue at the base of the pion causing premature breakage of the pion. This fatigue is due to the drag force as the tool moves into the room. The latter is particularly high aluminum with high elastic limits (type 7xxx, Al-Cu-Li or aluminum on steel), very demanding for tools.
- Abrasive wear of the entire tool by friction in the welded material. This stress causes a wear of the forms guaranteeing a good kneading of the material (spiral of the shoulder, length and threading of the pawn).
Depending on the materials, we have developed FSW tools allowing a welding distance of more than 1500 m on all our Al / Al tools. We have designed a test bench to optimize the geometry of the tools. tools and their heat treatment to meet these requirements.
Performance of our tools
The professionals at FSW Friction Stir Welding frequently encounter the following defects in their welding:
- Porosity continues along the weld (wormhole)
- Lack of penetration at the root of the weld
- Hang (typical defect of transparency welding)
- Burr on solder edges (flash)
We worked on the geometry of the tool to:
- Eliminate solder defects
- Maximize productivity (faster welding) thanks to the specific geometry of the tool
- Increase their lifespan
- Reduce effort on the tool to dramatically reduce damage from cyclic fatigue
- Optimize geometry and heat treatment to resist abrasive wear
"What is important for our welds is first to find the right parameters. We made several series of hundreds of pieces with Stirweld FSW tools. The welds are clean, reliable and reproducible."
ALain LOZACH - Research & Developpment Manager Cap Profilé - CALIP GROUP
Our FSW tools undergo a demanding quality control and the optimized heat treatment guarantees the consistency of their mechanical properties. The design of our tools is the result of many years of research. We invite you to read Dr. Dubourg's publication "Design and Propertoes of FSW Tools: A Literature Review".
Download the study: Dubourg - 6e FSW Symposium - Tools Review - Paper Finale
Ease of use
We made the choice of standardizing attachments with the Whistle Notch system. This solution allows for quick insertion and removal of the tool. The axial position is guaranteed, the risk of damage to the housing when the tool change is canceled.
Discover in image below the simplicity of setting up our tools
Each Stirweld FSW tool has a number for strict identification. It is therefore possible:
- know precisely the metric of the tool, thanks to the overlap with the workshop register
- to identify with certainty the type of tool and the nature of the welds for which it is intended.
Our tools are mass-produced to reduce the unit cost.