How FSW helped a foundry win an industrial project
Assemblies involving screws, gaskets, and additional components can generate significant costs. In this customer case study, discover how an aluminum foundry used Friction Stir Welding (FSW) to address this challenge and secure a new industrial project.
The challenge: reducing production costs for a complex aluminum assembly
Kovolis Hedvikov manufactures aluminum cast components. As part of an industrial project for a customer, the company sought to reduce the production costs of a complex assembly.
A costly traditional assembly for the end customer
Founded in 1816, Kovolis Hedvikov is a Czech manufacturer specializing in high-pressure aluminum die casting.
The company supplies technical components to demanding industries such as automotive, power electronics heat exchangers, air brake systems, and turbochargers.
For a new project, the end customer assembled an aluminum cooling housing using a sheet metal cover fastened with screws. Sealing was achieved through a gasket placed between the cover and the cast component.
The FSW Seamer fully leverages Stirweld’s expertise and the advantages of friction stir welding:
For Kovolis Hedvikov, the challenge was not simply to manufacture the casting. The company needed to propose a solution that would simplify the assembly while reducing the overall cost of the final product.
The limitations of conventional joining processes for high-pressure die castings
The challenge was even greater because high-pressure die cast components are known to be difficult to weld. Porosity and internal defects commonly found in cast parts can make conventional welding processes such as TIG, MIG, or laser welding more challenging to implement reliably.
The objective was therefore clear: replace a costly mechanical assembly with a solution that was simpler, more cost-effective, more reliable, and fully suited to the constraints of high-pressure aluminum die casting.
The solution: integrating a Stirweld FSW head on an existing machining center
Kovolis Hedvikov chose to replace the screwed assembly with Friction Stir Welding (FSW) to reduce the assembly costs of the cast component while also improving sealing reliability. The company selected Stirweld’s FSW solution, which can be integrated directly onto a machining center and is backed by comprehensive technological support throughout the project.
FSW: a welding technology well suited to aluminum die castings
High-pressure die cast components are often difficult to join using conventional welding processes. Porosity and internal defects generated during the casting process can make it challenging to produce reliable welds.
However, a technology shaping the future of industrial manufacturing is available: Friction Stir Welding (FSW). This solid-state joining process offers several advantages that make it particularly suitable for producing strong, leak-tight joints on this type of component:
The Stirweld solution: an FSW head that can be integrated on an existing machining center
Kovolis Hedvikov initially worked with Stirweld’s Friction Stir Welding experts to produce prototypes aimed at validating the process and demonstrating its feasibility to the end customer.
Following successful trials, the choice of Stirweld’s FSW solution became clear for two key reasons: an FSW system that could be easily integrated into the existing production line, and comprehensive technological support throughout every stage of the industrial project.
The Stirweld solution: an FSW head that can be integrated on an existing machining center
Stirweld’s FSW solutions are designed to integrate seamlessly with machining centers and robotic spindles.
At Kovolis Hedvikov, the standard FSW head was installed directly on a HAAS machining center already available in the workshop, eliminating the need for additional floor space or investment in a dedicated welding machine.
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Technical support from friction stir welding specialists
Beyond the FSW equipment itself, Kovolis Hedvikov was also looking for a partner capable of supporting the deployment of Friction Stir Welding technology.
Stirweld provided its expertise throughout the different stages of the project, including design adaptation, welding parameter definition, FSW tool selection, and support during the industrialization phase.
According to Vlastimil Bryksí, Technical Director of Kovolis Hedvikov, “Stirweld is not only an equipment supplier; it is a technology provider.”
“Stirweld is not only an equipment supplier; it is a technology provider.”
Vlastimil Bryksí, Technical Director of Kovolis Hedvikov
FSW results: a successful industrial project and greater customer value
The adoption of Friction Stir Welding not only addressed a technical challenge, but also gave Kovolis Hedvikov the ability to offer a more competitive and differentiated solution to its customer.
FSW expertise: a key asset from the quotation stage
Even before winning the project, the prototype trials enabled Kovolis Hedvikov to gain initial experience with the process and demonstrate its feasibility to the end customer.
This stage played a decisive role in preparing the proposal. As the company’s Technical Director points out: “Without experience with the process, we would not been able even to quote the project.”
This feedback highlights a point that is often overlooked: to fully leverage the potential of FSW, process expertise is just as important as the technology itself.
FSW: a decisive factor in securing the project
In this project, Friction Stir Welding proved to be much more than an efficient joining solution. It became a clear competitive advantage.
The combination of a simplified design, reduced assembly costs, and the expertise developed around the process enabled Kovolis Hedvikov to offer a compelling solution that met its customer’s expectations.
This statement perfectly illustrates the impact FSW can have on an industrial company’s competitiveness. In some cases, it does more than improve a product: it directly contributes to winning new business opportunities.
The added value of friction stir welding
Beyond this project, Kovolis Hedvikov now sees Friction Stir Welding as a driver for business growth.
Thanks to this technology, the foundry can offer higher-performance solutions, address new joining challenges, and help its customers optimize their products.
As the company’s Technical Director explains: “Friction Stir Welding is important for us. It enables us to offer to our customers more added value.”
This ability to create added value is further strengthened by Stirweld’s ongoing support, both during the launch of new projects and throughout serial production.
Video: how FSW helped a foundry win an industrial project
This video shows the Friction Stir Welding operation performed on the aluminum cooling housing and illustrates how the technology contributed to the success of the project.
Key take aways: FSW as a competitive advantage for aluminum die casters
This customer case study demonstrates that Friction Stir Welding is not just a technical innovation, but also a business enabler:
With its ability to integrate directly onto machining centers and the comprehensive support provided by its experts, Stirweld positions FSW as an accessible and strategic technology for the aluminum die casting industry.
Want to gain a competitive edge with FSW?
As this case study demonstrates, Friction Stir Welding can become a decisive competitive advantage when pursuing new business opportunities and industrial projects.
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