Why does prototyping help to choose the right metal welding technology?
There are hundreds of different ways of welding metals. So how do you make the right choice between traditional methods and more recent technologies such as friction stir welding (FSW)? In this selection process, prototyping plays a key role in the product design, development and validation phases. Find out how this crucial step contributes to the success of your industrial projects.
What is an engineering office with a prototyping service specialized in metal welding?
Regardless of the industry to which they belong, engineering offices with a prototyping service perform the same function but have specific features that reflect their particular expertise.
Engineering offices with a prototyping service are an essential link in the industrial production chain
In the industrial sector, an engineering office with a prototyping service produces preliminary versions of a product or its component parts. These first versions, known as prototypes, are used to ensure that the manufactured item meets expectations, before launching full-scale production. Once validated, the prototype serves as a model for mass production: it is reproduced identically in large quantities.
For smaller-scale requirements, the prototyping office can also be called upon to manufacture one-off parts or small series.
In the world of metal welding, prototyping is particularly useful for testing and validating the assembly of welded elements. The prototyping office first identifies the most appropriate welding technique for the project, then seeks to fine-tune its parameters, such as temperature, speed and pressure, to guarantee optimum weld joint quality. Finally, destructive and non-destructive tests are carried out on the prototype to assess weld quality.
Specific features of engineering offices with a prototyping service in the metal welding field
Welding techniques used
Engineering offices with a prototyping service office specialized in metal welding master one or more techniques from among the three main categories of welding processes:
To develop and manufacture prototypes, this type of entity has specialized equipment, customized tooling, digital simulation tools and a test laboratory.
Profiles within engineering offices with a prototyping service specializing in metal welding
Engineering offices with a prototyping service are made up of complementary profiles whose respective expertise covers the design, manufacturing and validation stages of prototypes. Although the number of people working in a such department varies according to the size of the company, here are the main positions:
Who can request a welded part prototype?
There are many more professionals interested in metal prototypes, in a wide range of sectors. However, the question of prototyping is common to every project, and it’s worth asking when it’s appropriate.
Industries requiring welded parts
Companies needing to weld metal parts belong mainly to these industries:
Other sectors may also be involved, such as telecommunications, medicine, agriculture, etc. In short, any company needing to assemble metal parts is likely to call on the services of a specialized prototyping office.
When should a prototype be made for welding a metal part?
Whatever your industrial sector, it all starts with a simple objective: to weld metal parts, such as aluminum, copper, magnesium, steel and so on.
There are 2 possible scenarios:
Why call on an engineering office with a prototyping service?
There are several reasons why a prototype of a welded part is such solid evidence when it comes to making a decision. And in the specific case of a call for tenders, the prototype becomes an undeniable asset in winning a contract.
5 good reasons to ask for a prototype of a welded part
Prototyping is crucial to choosing the right welding technology for a metal part, for 5 good reasons:
Special case of a call for tenders
In a call for tenders, a company looks for the supplier best suited to its project, according to precise specifications.
The prototype therefore enables the company to ensure that the bidder has mastered the welding process used and is capable of meeting the technical requirements of the specifications. This is more important when the project is complex or innovative.
The prototype also ensures that the choice is not made solely on the basis of cost or time, to the detriment of quality. What’s more, any weak points are immediately identified, making the project more secure.
How is prototyping carried out for a friction stir welding project?
Friction stir welding is a revolutionary technology that offers several significant advantages over traditional welding techniques, particularly when it comes to joining aluminum components. At Stirweld, the prototyping process for a friction stir welded part is divided into 4 main stages.
Step 1: Study FSW feasibility and make design recommendations
The signing of a mutual Non-Disclosure Agreement (NDA) marks the start of the project study.
There are two possible scenarios:
Once all this information is available, the experienced welding engineer is able to thoroughly analyze the FSW project. Criteria examined include flatness, pressure resistance, mechanical strength, welding area, tool space requirements, optimum welding sequence and exit hole positioning.
The result of this analysis is a document listing all the design modifications required and whether they are mandatory or recommended for optimum FSW welding.
Step 2: Design and manufacture the clamping tooling
To be successful, friction stir welding must meet a number of conditions, including the use of suitable clamping tooling. As each FSW welding project is unique, it is essential to develop specific tooling to ensure that the part is held securely when the machine is in operation. Before manufacturing this tooling, our experts analyze the geometry of the part to be welded to locate the critical zones, define the appropriate clamping force, and determine the path of the FSW tool.
Step 3: Determine FSW welding parameters
The main FSW welding parameters studied by our experts are listed in a document called the Welding Procedure Specification (WPSD). There are four of them:
Step 4: Weld your prototype thanks to friction stir welding
With the clamping tool set up and the welding parameters defined, all the conditions required for welding are in place. At last, the Stirweld FSW head goes into action! The welded prototype can then undergo various quality checks: air-tightness test, dye penetrant inspection, dimensional control, tensile tests, non-destructive tests, helium leak test, pressure tests.
During this final stage of prototyping, it is also possible to produce the first batches of parts, ranging from 10 to 500 units, depending on their complexity.
Why call on Stirweld to prototype your FSW welded parts?
As a specialist in FSW and an industry member of TWI (The Welding Institute), Stirweld’s mission is to make this revolutionary technology accessible to all companies needing to weld metal parts.
Accustomed to complex projects, our team is made up of highly qualified specialists, including Laurent Dubourg, a world expert in FSW with over 20 years’ experience, and IWE® (International Welding Engineer) certified engineers.
Our prototyping workshop is equipped with four high-precision machining centers and a versatile industrial robot. All these machines feature dedicated FSW solutions developed by Stirweld, enabling us to process all types of parts, whatever their shape or size.
But if Friction Stir Welding seems child’s play when you see the Stirweld head in action, it’s because the project has been well thought out upstream.
For each project studied, Stirweld’s prototyping department has 4 objectives:
The prototype produced is thus the guarantee of a successful industrial project!
Are you considering FSW for a project?
Our engineering office with a prototyping service is at your disposal to study the feasibility of your project and then to produce prototypes. Contact us to make sure that friction stir welding is the right choice for your project!
