Our experts assist you in the implementation of the welding parameters, the design of the clamping jig, the choice of FSW tools and the qualification of your applications. In FSW or FSSW, our experts will guide you towards the success of your innovative welding projects.
To identify the optimum FSW parameters
Qualification Tests (NDT) of pieces
According to ISO 25239 standards (traction, fatigue, corrosion, leak)
Post-FSW Operations Test
Surface treatment (OAS or OAC anodizing, nickel plating,
painting), heat treatment, finishing, machining
Non Destructive Testing (NDT)
Liquid penetrant (LPI), X-ray, Ultrasound (US).
D-MOS and Q-MOS (WPS) according to ISO 25239 standards
Leading you to the success of your FSW project
Our specialist team supports you in the implementation of FSW in your company.
The optimization of FSW parameters results in a perfect and reproducible welding operation.
The clamping of parts has a significant impact on your production rate and the weld quality.
We support you in the adjustment of the welding parameters and in the design of your clamping jigs.
FSW Industrial Study
Codesign of customer piece
We provide material strength analysis, based on customer’s burst and fatigue specifications. Then welded thickness is determined, and the adapted FSW tool is selected.
We perform FSW feasibility analysis, suggesting design adaptations to get the part ready for FSW and to optimize FSW process.
Design and manufacturing of clamping jig
It must be taken into account:
- Number of clamps
- Clamping force
- Tool wear
- Tool path
As clamping has an impact on your production rate and weld quality, we offer you our know-how for jig design.
We first design and manufacture a backing (anvil) that is placed under the part during FSW to support FSW vertical load.
Then we design and manufacture the clamping system to hold the part during welding, providing a 3-axis blocking: a good clamping system permits to avoid part opening, dragging and lifting, which is essential for a good weld quality.
Each clamping jig is unique, and requires much expertise that Stirweld is able to provide.
Welding parameters and quality control
FSW industrial study includes determination and optimization of welding process parameters, such as:
- Choice of the FSW tool
- Welding force
- Tool rotation speed
- Welding speed
- Plunging speed
These FSW parameters will optimize the part production while assuring a perfect and reproducible weld.
In addition, special attention must be paid to the position of the tool: where to place the advancing and the retreating side.
Our advice: always place the advancing side where there is more material or where the aluminium is more resistant.
To ensure that the parameters lead to a good weld quality, we perform destructive and non-destructive testing, according to customer specifications and FSW standard ISO 25239.
Weld of 5754-H111 aluminum with XES G10 / 10 steel after bending test (lap weld control).
Bending test according to ISO 25239 (butt weld)
Tensile test on FSW welded part (fracture outside the weld).
All this information is synthesized is a document called WPS: Welding Procedure Specification.
Possible certification steps :
DMOS-QMOS approach applied to FSW welding (mainly used in aerospace and automotive).
The DMOS (welding procedure EN ISO 15609) lists the welding materials and the steps of the welding process :
-preparation before welding,
-setting welding parameters,
-right choice of FSW tool.
The QMOS (welding procedure qualification) occurs during the welding operation, carried out in strict execution of the associated DMOS. It certifies the reliability of the weld concerned.
For FSW projects that do not require an aeronautical standardization approach, we apply the standard ISO 25239.
Manufacturing of first batches
Stirweld can take over manufacturing of the first batches at its own facilities, from a size of 10 to 500 parts. Once the parts are welded and quality control has been performed, the parts are shipped either to you or to the final customer.
Support & optimization after launch in Customer’s facilities
As an example, Stirweld support can be advise on quality control procedure, with an evolving testing frequency. If anything wrong happens, we are here to help you solve problems, dealing with parameters, clamping jig, …
Example of quality control procedure:
Perform 5 metallographic cross sections and analysis per part on indicated zones.
- The first part at the beginning of each shift (3 parts/day)
- If all parts OK during one entire week: one part per day
- If all parts OK during one entire month: one part per 2 days
If any part is not OK in any of the steps, Stirweld support will quickly help to solve it.
Stirweld has already supported the implementation of FSW through this industrial study to companies like:
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Chief Technical Officer