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    • FSW HEADS
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      • FSW: a cost-killer in the aeronautics industry
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      • FSW spindle for robot
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logo Stirweld France 2021
  • Stirweld Products
    • FSW HEADS
      • FSW standard head V3
      • FSW head with retractable pin
      • FSW Spindle for robot
      • Stirweld FSW machine
    • FSW TOOLS
      • High strength aluminium
      • Standard aluminium
      • Aluminium silicon
      • Aluminium steel
      • Aluminium copper
      • Stirweld Tool Holder
      • FSW tools catalogue
    • FSW ACCESSORIES
      • Temperature measurement
  • FSW Services
    • FSW prototyping
    • FSW clamping system
  • FSW Technology
    • FSW process
    • Principles & Trends
  • FSW Applications
    • Liquid cold plates
    • Heat sinks for e-mobility
    • Aluminium tank
    • Copper applications
    • FSW stiffened panels
    • Other FSW applications
    • FSW Applications
  • FSW resources
    • ARTICLES
      • FSW: a cost-killer in the aeronautics industry
      • How to choose FSW tool for my application
      • 4 essential elements for high quality FSW welding
      • More
    • WHITE PAPERS
      • Thermal Management: FSW liquide cold plate
      • FSW x Rheocasting
      • FSW Water heat sink for e-mobility
      • More
    • WEBINARS
      • FSW: all you need to know about aluminium welding
      • Thermal management: liquid cold plate & FSW
      • FSW: die casting heat sink for e-mobility
      • More
    • VIDEOS
      • FSW spindle for robot
      • Liquid cold plates welded by FSW
      • Satellite thermal Management
      • More
  • About
    • Who is Stirweld
    • FAQ
  • Contact
  • EnglishEnglish
    • FrançaisFrançais
    • DeutschDeutsch
    • EspañolEspañol
    • PolskiPolski
    • TürkçeTürkçe
    • ItalianoItaliano

FSW PROTOTYPING

want to know more

FSW Prototyping

Stirweld accompanies you in your first steps in FSW technology to achieve high quality results. We follow a rigorous process in which we work together in each and every stage.
FSW technology

Codesign of customer piece

We provide material strength analysis, based on customer’s burst and fatigue specifications. Then welded thickness is determined, and the adapted FSW tool is selected.

We perform FSW feasibility analysis, suggesting design adaptations to get the part ready for FSW and to optimize FSW process.

FSW process

Design and manufacturing of clamping jig

FSW tool deeps vertically

It must be taken into account:

  • Geometry
  • Number of clamps
  • Clamping force
  • Tool wear
  • Tool path

 

More about clamping jig

Welding parameters and quality control

FSW industrial study includes determination and optimization of welding process parameters, such as:
how FSW Stirweld tool fonctions
 

  • Choice of the FSW tool
  • Welding force
  • Tool rotation speed
  • Welding speed
  • Plunging speed

These FSW parameters will optimize the part production while assuring a perfect and reproducible weld.

In addition, special attention must be paid to the position of the tool: where to place the advancing and the retreating side.
FSW advancing & retreating side
Our advice: always place the advancing side where there is more material or where the aluminium is more resistant.
To ensure that the parameters lead to a good weld quality, we perform destructive and non-destructive testing, according to customer specifications and FSW standard ISO 25239.
T-piece FSW weld
Weld of 5754-H111 aluminum with XES G10 / 10 steel after bending test (lap weld control).
Stirweld's bend tests according to ISO 25239
Bending test according to ISO 25239 (butt weld)
FSW tensile test
Tensile test on FSW welded part (fracture outside the weld).

All this information is synthesized is a document called WPS: Welding Procedure Specification.

Specification for Friction Welding of Metals
Stirweld meets requirements in greater quality and safety for people, the environment and technology
Possible certification steps :

DMOS-QMOS approach applied to FSW welding (mainly used in aerospace and automotive).

The DMOS (welding procedure EN ISO 15609) lists the welding materials and the steps of the welding process :

-preparation before welding,
-setting welding parameters,
-right choice of FSW tool.

The QMOS (welding procedure qualification) occurs during the welding operation, carried out in strict execution of the associated DMOS. It certifies the reliability of the weld concerned.

For FSW projects that do not require an aeronautical standardization approach, we apply the standard ISO 25239.

 

FSW Welding Procedure Specification

Extract of Stirweld WPS (Welding Procedure Specification ISO 25239)

Manufacturing of first batches

Stirweld can take over manufacturing of the first batches at its own facilities, from a size of 10 to 500 parts. Once the parts are welded and quality control has been performed, the parts are shipped either to you or to the final customer.

OUR PROTOTYPING FACILITIES

Stirweld Breton Millfly

BRETON MILLFLY

8 500 mm

3 900 mm

900 mm

Stirweld Hass VF-3

HAAS VF-3

1 000 mm

500 mm

400 mm

Stirweld Doosan Minx

DOOSAN MINX

2 400 mm

900 mm

700 mm

Support & optimization after launch in Customer’s facilities

As an example, Stirweld support can be advise on quality control procedure, with an evolving testing frequency. If anything wrong happens, we are here to help you solve problems, dealing with parameters, clamping jig, …
Example of quality control procedure:

Perform 5 metallographic cross sections and analysis per part on indicated zones.

  1. The first part at the beginning of each shift (3 parts/day)
  2. If all parts OK during one entire week: one part per day
  3. If all parts OK during one entire month: one part per 2 days

If any part is not OK in any of the steps, Stirweld support will quickly help to solve it.

FSW quality control procedure

Stirweld has already supported the implementation of FSW through this industrial study to companies like:

Our 3 steps process

How to successfully implement FSW in your company?

FSW coaching for my project?

we can guide you in every step of your project

I need expert advice
Send your message

FSW is now accessible


More than an FSW supplier, Stirweld is also a partner for your FSW projects: studies, qualifications, training, FSW heads for MOCN & tools. Expertise and advice in addition. We accompany you all over the world and help you to implement this new technology. Contact us Stirweld sur Linked in Stirweld sur Twitter Youtube Stirweld
STIRWELD WORKSHOP

Bâtiment ENS, Campus de Ker lann, Avenue Robert Schuman, 35170 Bruz, FRANCE

+33 (0)7 63 85 42 82

STIRWELD FRANCE HEADQUARTERS

1 rue Jean de Thévenot, 35 760 Saint Grégoire, FRANCE

contact@stirweld.com

USA STIRWELD INC.

2791 Research Drive, Rochester Hills, MI 48309, USA

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