FSW APPLICATION

Bus Bar Welded by FSW

Enhancing reliability and efficiency in bus bar assemblies with Friction Stir Welding.

Why Choose Friction Stir Welding for Your Bus Bar Assembly?

Friction Stir Welding (FSW) offers a transformative solution for bus bar assembly, providing numerous advantages over traditional methods. From enhanced performance to significant cost savings, FSW stands out as the optimal choice for modern electrical systems.

No risk of unscrewing

Offers superior fatigue resistance, doubling the durability compared to traditional screwing methods.

Cost divided by 3

Reduces welding costs by up to 3x compared to conventional screwing techniques.

friction stir welding for copper/aluminium welding

Solution for copper shortage

Enables the use of aluminium as a viable alternative, making copper-aluminium welding feasible.

Perfect conductivity

Achieves weld conductivity that is twice as efficient as traditional screw connections.

Technical Specifications of FSW-Welded Bus Bars

Friction Stir Welding provides a cost-effective alternative for welding copper components, surpassing traditional methods in both thermal conductivity and mechanical strength. By replacing arc welding or brazing, FSW enhances the quality of the junctions and significantly improves mechanical resistance. This technique is suitable for welding both Cu/Cu and Al/Al bus bars, making it versatile for various applications. One prominent sector utilizing this technology is the energy industry, where the durability and efficiency of FSW-welded copper components are critical.

In the welding of brass components, FSW offers significant advantages by reducing milling volume, which in turn lowers manufacturing costs. By replacing brazing, FSW not only enhances the quality of junctions but also improves mechanical resistance. This method is particularly beneficial in industries such as ornamental and nautical, where both aesthetic and structural integrity are paramount.

friction stir welding of brass components

replacement of copper by aluminium in bus bars

FSW enables the seamless metallurgical joining of copper and aluminum, addressing the challenge of minimizing electrical resistivity. The use of aluminum as a replacement for copper results in substantial cost and weight savings, as aluminum is both less expensive and lighter than copper. Moreover, FSW allows for the defect-free welding of aluminum and copper, offering a more reliable alternative to traditional screwing methods. The energy sector, in particular, benefits from the efficiency and reliability of FSW in applications requiring the combination of these two metals.

See Friction Stir Welding Applied to Bus Bars in Real-Time

Comparing FSW to Traditional Bus Bars Assembly Technique

Friction Stir Welding vs. Screwing

No risk of unscrewing: Unlike screw-based assembly, Friction Stir Welding eliminates the risk of components loosening over time, which is essential in applications where safety and reliability are critical. Additionally, without screws, there is no fire risk from loose connections or mechanical failures, making it a safer and more robust solution for busbar management.

Enhanced electrical conductivity: Friction Stir Welding significantly improves electrical conductivity, doubling it compared to screwed assemblies. This is achieved through the continuous metallurgical junction created by FSW, forming a perfect, seamless connection between parts that reduces electrical resistance. This results in a more efficient and stable current transfer, ideal for high-performance electrical applications.

Reduced assembly costs: The FSW process also cuts assembly costs by up to three times compared to screwing. Without the need for threading operations, screws or tightening controls, the manufacturing process is simplified, reducing both time and associated costs. This enables faster and more economical production without compromising the quality or durability of the assembly.

Bus Bars: Essential Components Across Key Industries

Bus bars are fundamental components in electrical power distribution, providing efficient, reliable and scalable solutions that are critical to the operation of various high-demand industries. Their ability to handle large currents, reduce system complexity and enhance safety makes them a preferred choice for modern engineering applications. As technology advances and the demand for robust electrical infrastructures grows, the role of bus bars becomes even more crucial.

Whether in aerospace systems, automotive applications, railway networks, defense technology, energy production, or shipbuilding, bus bars ensure the seamless integration and operation of complex electrical systems, supporting everything from day-to-day functionality to mission-critical operations.

Aerospace

Powering the Future of Aviation

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Automotive

Driving Electrical Innovation

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Railway

Ensuring Safe and Reliable Journeys

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Defense

Supporting Mission-Critical Operations

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Shipbuilding

Navigating Innovation in Maritime Power

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Energy

Empowering Sustainable Power Solutions

Dive Deeper: Comprehensive FSW Resources

Dive into the realm of Friction Stir Welding technology with engaging webinars, insightful blog posts, and in-depth whitepapers.

Webinar – 40 min – Replay on demand

Friction Stir Welding unveiled

Unlock the potential of Friction Stir Welding with our detailed webinar replay. Gain valuable insights into the process, its applications, and how to optimize it for your needs. Ideal for those looking to elevate their expertise in welding technology.

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Blog articles – 5 min

Why FSW of aluminium is the future of industrial manufacturing?

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How much will it cost you to weld your part by FSW?

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Practical guide – 20 min

5 essential steps to master Friction Stir Welding

Master Friction Stir Welding with our step-by-step guide. From setup to certification, learn to improve your welds and enhance efficiency!

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practical guide of friction stir welding pdf

White paper – 20 min

Friction Stir Welding for dummies

Explore the fundamentals and advantages of Friction Stir Welding through our detailed beginner’s white paper to understand this innovative technology.

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Ready to Revolutionize Your Bus Bar Manufacturing?

Discover how Stirweld’s innovative Friction Stir Welding solutions can revolutionize your bus bar assemblies and more. Let’s discuss how we can meet your specific industry needs.

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