FSW APPLICATION
Additive Manufacturing Part Welded by FSW
Solid-state FSW enables the defect-free assembly of 3D-printed aluminum and copper parts, preserving mechanical strength.
Why Choose Friction Stir Welding for Your Additive Manufacturing Parts?
Additive manufacturing enables complex geometries, but joining large 3D-printed parts remains a challenge. Friction Stir Welding offers a solid-state solution to assemble SLM-fabricated aluminum and copper components without defects, preserving their mechanical and functional properties.
100% Leak-Proof
The solid-state FSW process ensures fully sealed joints, eliminating porosities and guaranteeing leak-free performance.
High Mechanical Strength
FSW maintains the mechanical properties of 3D-printed materials, creating joints with strength close to the base metal.
Multi-Material Capability
Proven on both aluminum and copper AM parts, FSW enables hybrid assemblies with excellent conductivity and strength.
Scalable Manufacturing
Allows the reliable assembly of large 3D-printed components, paving the way for industrial-scale additive manufacturing.
Technical Specifications of FSW-Welded Additive Manufacturing Parts
In Additive Powder Bed Manufacturing (SLM), aluminum-silicon alloys often exhibit micro-porosities and heterogeneous microstructures that can compromise joint performance. Friction Stir Welding (FSW) offers a robust solution by ensuring full consolidation of the material in a solid state:
Once welded, the aluminum-silicon component is machined to reach its final geometry. Stirweld’s FSW head enables both operations (welding and machining) on the same CNC, offering a flexible and cost-efficient production route:
FSW of 3D-Printed Copper: Understanding the Thermal Challenge
Additive manufacturing of copper enables the production of complex, high-conductivity parts used in advanced electronic and thermal systems. However, welding copper presents a unique challenge due to its exceptional thermal conductivity.
During Friction Stir Welding, the intense frictional heat generated at the tool/workpiece interface is rapidly conducted away by the copper, concentrating the heat within the tool itself. This phenomenon highlights both the thermal efficiency of copper and the robustness of the FSW process.
The result: a defect-free, fully consolidated joint that maintains the electrical and mechanical properties required for high-performance applications.
Additive Manufacturing Parts: Key Concerns for Critical Sectors
Additive manufacturing enables the production of lightweight, complex and highly optimized metal components used in advanced engineering systems. However, many of these parts require reliable assembly to reach dimensions, functions or performance levels that exceed the capabilities of a single print. Solid-state Friction Stir Welding provides a powerful solution by ensuring defect free joints, full sealing and exceptional mechanical strength.
Thanks to its ability to preserve material integrity and eliminate porosities, FSW is particularly valuable for additive manufacturing parts used in strategic industries where reliability, thermal stability and structural performance are essential:
Learn More: Comprehensive FSW Resources
Explore a curated selection of resources designed to help you deepen your understanding of Friction Stir Welding. These materials provide technical insights into the principles of solid state welding, process parameters, tooling considerations and industrial applications. Whether you are evaluating FSW for a new project or looking to strengthen your technical knowledge, these resources offer a comprehensive foundation for advancing your expertise.
Webinar – 45 min – Replay on demand
FSW Basics: Unlocking the Power of Friction Stir Welding
This webinar provides a clear introduction to Friction Stir Welding (FSW), focusing on how the process operates, which parameters are critical to success, and how to detect and avoid typical weld defects. It also explores industrial applications and practical ways to improve FSW performance.
Blog articles – 5 min
Prototyping: an essential step in the choice of welding process
Quality Control of Friction Stir Welding
White paper – 20 min
Friction Stir Welding for dummies
This white paper breaks down FSW into simple, practical concepts, giving beginners a clear overview and essential guidance to grasp the process with confidence.
White paper – 20 min
5 essential steps to master Friction Stir Welding
Explore our expert guide on Friction Stir Welding. Gain insights into each stage, from initial planning to expert certification, to elevate your welding projects.
Turn Additive Manufacturing into Industrial Production
Discover how Friction Stir Welding enables reliable, leak proof and high strength assembly of additive manufacturing parts for critical applications.
