Friction Stir Welding: The future of aluminium welding

Friction stir welding of aluminium parts is simple, repeatable, and affordable. However, this welding technology is still barely known to many. Read on and find out why you should know about it!

The aluminium sector is booming — it’s the fastest-growing light metal, expanding at a rate of 6% per year!
Its use spans a wide range of industries: from window frames to automotive heat sinks, aluminium stiffened panels, and aircraft components.This diversity of applications is largely due to the unique properties of aluminium alloys: low density, non-toxic, excellent thermal conductivity, corrosion resistance, and the ability to be easily formed, machined, or cast.
It’s also the sixth most ductile metal and the second most malleable.
And above all, its standout advantage is its lightness.

Every sector involved in transport is increasingly turning to aluminium, seeking efficient and economical solutions for processing and assembly. That’s why, when it comes to the welding of aluminium, the high performance of the Friction Stir Welding process is widely recognised — especially for its consistency and strength.

This innovative welding technology continues to evolve rapidly and is already used in a wide range of applications: automotive, aeronautics, space, energy, and even nuclear.

Today, aluminium is truly everywhere. It is used in the construction of aeroplane fuselage components, launchers like rockets, boat covers, and many car parts — including heat sinks, inverters, and thick aluminium structures.

Friction Stir Welding Technology: Advantages for Aluminium Welding

Economic Advantages of FSW for Aluminium Welding

Significant savings in cycle time and increased reproducibility of assembly operations thanks to friction stir welding process automation.

No material input, no preparation of joints, and low energy consumption — making it a highly efficient welding technology.

Mass savings by eliminating rivets or reducing the thickness of the assembly — especially for welding aluminium alloys and thick aluminium structures.

In multi-material assemblies, expensive materials like magnesium alloy or titanium alloys are used only where needed, while non-critical parts are made from more affordable materials — optimising welding parameters.

Reduced welding costs due to fewer consumables — 1 tool can weld over 1,500 meters of aluminium.

Less post-weld inspection required, further lowering production costs.

If we talk specifically about the Stirweld FSW head, we find two great advantages to add: the investment is limited since the welding is carried out on an existing CNC machine and the head is available for renting (starting from 1900 € / month).

Technological advantages of Friction Stir Welding for aluminium welding

Friction stir welding of aluminium allows the joining of multiple grades together — without hot cracking or porosity — enabling heterogeneous assemblies.

The FSW process ensures excellent thermal and electrical conductivity, making it particularly well-suited for aluminium extrusion and the welding of aluminium panels.

Operating modes can be qualified under international welding standards, such as ISO 25239.

This welding procedure is compatible with all aluminium alloys (1xxx to 7xxx series), and also works with aluminium foundry parts, including die-cast aluminium.

The process ensures welds with no leakage, whether it’s water, acid, or air — a major asset for aluminium ships and hydro marine aluminium assemblies.

In multi-material assemblies, FSW allows full exploitation of each material’s strengths: lightness, resistance, conductivity, and hardness — making it a preferred joining process.

After welding, forming operations such as stamping or bending the welded aluminium sheet are possible — with no risk of cracking.

With a welding capacity up to 20 mm, FSW is ideal for thick aluminium applications.

It delivers high mechanical strength, with fatigue performance of friction stir welds close to the original base material — a key advantage in demanding sectors.

No smoke emissions and no consumables, leading to savings in raw materials and reduced welding costs.

By enabling the production of lighter aluminium parts while maintaining their mechanical properties, friction stir welding helps reduce fuel consumption in the automotive, aeronautical and general transport sectors. As a result, greenhouse gas and pollutant emissions are also reduced.

No ozone generation, unlike arc welding or traditional fusion welding techniques, making FSW a more environmentally friendly welding technology.

FSW technology has been proven to be highly effective for the welding of aluminium parts. What are you waiting for to learn more about it?

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