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FSW APPLICATION

Tailor Welded Blanks Welded by FSW

High performance Tailor Welded Blanks (TWB) through Friction Stir Welding for stronger joints, reduced distortion and lightweight designs.

See the FSW Tailor Welded Blank in action

TWB welded by FSW

Why Choose Friction Stir Welding for Your Tailor Welded Blanks?

Friction Stir Welding (FSW) enables the production of high quality Tailor Welded Blanks with superior mechanical properties and minimal distortion. Compared with conventional fusion welding processes, FSW delivers stronger joints, greater process stability, and new possibilities for joining advanced lightweight materials.

no risk of unscrewing in bus bars

Stronger Joints

Delivers high joint strength and excellent fatigue performance for demanding structural applications.

minimal distortion in the weld

Minimal distorsion

Low heat input reduces residual stresses and preserves dimensional accuracy.

dissimilar material joining with FSW for tailor welded blanks

Dissimilar material joining

Reliably welds aluminium alloys with different grades or thicknesses.

better conductivity than screwing

Defect free welds

Eliminates porosity, hot cracking, and other fusion welding defects for consistent weld quality.

Technical Specifications of FSW-Welded Tailor Welded Blanks

stamping after friction stir welding - tailor welded blank

Friction Stir Welding enables Tailor Welded Blanks to undergo demanding stamping and flow forming operations while preserving joint integrity. The solid-state welding process produces high quality welds that withstand severe plastic deformation, making FSW an ideal solution for lightweight formed components.

Dome testing confirms the excellent formability of FSW-welded Tailor Welded Blanks under high plastic strain. The test is performed on both the weld side and the root side. No failure is observed in the weld, demonstrating its high quality, while failure occurs only in the Heat Affected Zone (HAZ).

dome test after FSW in a tailor welded blank

free forming after friction stir welding — Collaboration with Machina Labs

FSW welds maintain their integrity during complex free forming operations. The high weld quality enables deep plastic deformation without failure, allowing manufacturers to produce complex geometries while ensuring reliable mechanical performance.

See Friction Stir Welding Applied to Tailor Welded Blanks in Real-Time

Comparing FSW to Traditional Tailor Welded Blank Assembly Techniques

Friction Stir Welding vs. TIG and MIG

Joint quality: FSW provides high mechanical resistance while avoiding fusion related defects such as porosity, resulting in reliable joints for Tailor Welded Blanks.

Aluminium alloy versatility: Unlike TIG/MIG, which is mainly suited to 5xxx and 6xxx aluminium alloys, FSW can weld all aluminium alloy families, expanding the possibilities for Tailor Welded Blank design.

Lower consumable requirements: FSW requires only the welding tool as a consumable, eliminating the need for gas, wire feeding and electrodes used in conventional TIG/MIG welding.sts.

Improved working environnment: As a solid state process, FSW avoids the smoke, shielding gases and electrical risks associated with conventional TIG/MIG welding.

Friction stir welding versus MIG-TIG for tailor welded blank manufacture

Friction Stir Welding vs. Laser Welding

Greater weld penetration: FSW can achieve weld penetration of up to 10 mm, compared with 3 mm for laser welding, enabling the assembly of thicker Tailor Welded Blanks.

Higher mechanical resistance: FSW provides up to twice the mechanical resistance of laser welding, delivering stronger and more reliable joints for Tailor Welded Blanks.

Lower consumable requirements: Friction Stir Welding relies on the FSW tool as its consumable, while laser welding requires gas and filler metal.

Higher energy efficiency: FSW reaches 90% electrical energy efficiency compared with 20% for laser welding, significantly reducing the energy losses associated with the welding process.

friction stir welding versus laser welding for TWB manufacture

Tailor Welded Blanks: Key Applications Across Industries

Tailor Welded Blanks enable manufacturers to combine different thicknesses and material properties within a single component, optimizing weight and structural performance. This versatility makes TWBs particularly valuable in industries where lightweight design, strength and material efficiency are essential.

battery tray automotive

Automotive

Lightweight structural components combining different thicknesses for optimized strength and weight reduction.

battery tray aeronautics

Space

Weight-optimized structures designed to meet demanding mechanical performance requirements.

battery tray energy

Defense

High-performance structural components combining strength, durability and reduced weight.

battery tray data centers

Aeronautics

Lightweight structural solutions optimizing material distribution while maintaining mechanical performance.

battery tray railways

Railways

Large lightweight structures combining optimized material use with high structural performance.

battery tray shipbuilding

Shipbuilding

Weight-optimized panels and structures designed for demanding marine applications.

Learn More: Explore FSW Technology

Interested in the technology behind FSW-welded Tailor Welded Blanks? Explore our technical resources to understand the FSW process, key welding parameters, quality control methods, and the steps required for successful industrial implementation.

Webinar – 45 min – Replay on demand

Master the Fundamentals of Friction Stir Welding

Discover the fundamentals of FSW, from process principles and key welding parameters to defect prevention and real industrial applications.

Blog articles – 5 min

Prototyping: an essential step in the choice of welding process

Limitation of Distortion in FSW Panels using Needle Peening

White paper – 20 min

Friction Stir Welding for dummies

Get a clear and accessible introduction to Friction Stir Welding, from its basic principles to its main benefits and industrial applications. An ideal starting point for anyone discovering FSW technology.

Download for free now

guide to understanding FSW technology

White paper – 20 min

5 essential steps to master Friction Stir Welding

Discover the key steps to successfully implement Friction Stir Welding, from defining your project requirements and welding parameters to achieving a reliable and qualified production process.

Download for free now

thermal management - FSW liquid cold plate

Ready to Bring FSW to Your Tailor Welded Blanks?

Discover how Friction Stir Welding can improve weld quality, formability and mechanical performance. Our FSW specialists can help you develop a reliable solution tailored to your materials, thicknesses and production requirements.

Speak with an FSW specialist