FAQs

How to manage temperature with the FSW head during FSW operations?

The welding temperature with the FSW head is managed according to 3 parameters:

  • the feed speed: the faster the FSW tool feeds, the colder the material will be
  • the rotation speed: the faster the tool rotates, the hotter the material will be
  • Z-force (which refers to the force exerted vertically during the welding operation): the more the FSW head presses on the parts to be joined, the hotter the parts will be.

It is important to control these 3 parameters to ensure a good and strong FSW weld.
To get an indication of the temperature during your welding operations, you can use Stirweld’s temperature measurement system.

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What is flash defect in FSW?

In welding, flash refers to the burr on the retreating side due to the rotation of FSW tool. The flash is the main defect that can be encountered duri...

These flashes are visible to the naked eye on the joint edges. It is more a question of an aesthetic imperfection. Indeed, this loss of plasticised material on the edge of the shoulder has no impact on the strength of the weld.

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What are the common weld defects?

There are 5 main FSW defects:

  • Flash or burr on the edges of the weld ;
  • Wormhole or tunnel which i.e. a porosity present on all or part of the length of the weld ;
  • Lack of penetration which is an internal defect of the weld ;
  • Hooking which i.e. a rise in surface of the material;
  • Kissing-bond that appears when the adhesion is zero.

Flashes and wormholes are common defects in butt and through weld configurations. Find in our article detailed information on the main defects encountered in friction stir welding.

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What about the life of the tool? (in weld meter)

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The average life of our tools is 2000 metres of weld in a typical FSW configuration.
The life of the FSW tool varies depending on 2 key factors: the correct use of the tool and its settings. The most common causes of wear are cyclic fatigue at the pin and abrasive wear due to frictional action.
Its life will also depend on the thickness of the parts and the materials welded: aluminium/aluminium, aluminium/copper, aluminium/steel…

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Read MoreWhat about the life of the tool? (in weld meter)