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FSW APPLICATION

Bus Bar Welded by FSW

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

friction stir welding of bus bars

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 in bus bars

No risk of unscrewing

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

fsw cold plate

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.

better conductivity than screwing

Perfect conductivity

Achives electrical conductivity in the weld that is up to 10 times higher than screw connections.

Technical Specifications of FSW-Welded Bus Bars

thermal straps welding

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.

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.

thermal management aerospace

Aerospace

Powering the Future of Aviation

bus bars in automotive

Automotive

Driving Electrical Innovation

bus bars in railway

Railway

Ensuring Safe and Reliable Journeys

thermal management energy

Defense

Supporting Mission-Critical Operations

thermal management aerospace

Shipbuilding

Navigating Innovation in Maritime Power

thermal management energy

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.

Blog articles – 5 min

Why FSW of aluminium is the future of industrial manufacturing?

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

Practical guide – 20 min

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

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.

learn about Friction Stir Welding pdf

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.