In our modern world of manufacturing, staying ahead of the curve is crucial. At MTI, we pride ourselves on embracing innovative technologies that drive efficiency and quality. As industries race to keep up with emerging trends that meet today’s needs, Friction Stir Welding (FSW) stands out as the go-to technology. Today, we're thrilled to introduce the latest addition to our state-of-the-art facilities: another FSW machine.
Friction Stir Welding is revolutionising the welding industry. Invented in 1991, FSW offers unparalleled versatility and reliability, making it the go-to choice for industries ranging from automotive to aerospace.
But what sets FSW apart? Unlike traditional welding methods, FSW uses a non-consumable pin tool to generate frictional heat, creating strong, defect-free joints without melting the materials. This results in superior weld quality, reduced distortion, and enhanced mechanical properties.
Understanding Friction Stir Welding
So, how does Friction Stir Welding work?
The FSW process uses a non-consumable pin tool to create frictional heat between two materials. The pin tool begins to rotate and plunges into the two pieces of metal maintaining a downward (Z-axis) force. This is referred to as the plunge or entry hole at the start of the weld path. The rotating pin tool shoulder creates friction. The resulting friction then preheats the materials creating a plasticized state at a temperature range below the material melting point. The pin travels along the joint and consolidates the material along the weld profile/path while maintaining a downward force and Z-axis position. At the end of the weld path, the tool is withdrawn in the Z-axis.
Now that we've explored the intricacies of FSW, let's shift our focus to the dynamic landscape that has driven an unprecedented demand for this innovative technology.
Meeting the Demands of Modern Manufacturing
The automotive industry in particular is experiencing an unparalleled shift towards electrification (also known as e-mobility). Electric vehicles require new lightweight designs – a perfect match for FSW. Aerospace companies are also turning to FSW for its ability to join dissimilar and advanced materials, crucial for weight reduction and fuel efficiency.
At MTI, we listened to our customers and recognized the growing need for advanced FSW capabilities. That's why we invested in the FS-1, our new Friction Stir Welding machine housed at our U.S. contract welding facility. The FS-1 is equipped with several unique features that optimise the production process including an automatic tool changer, zero-point locator system, and a rotating head.
1. Automatic Tool Changer: Holds up to 40 different tools for seamless changeovers, increasing production efficiency. For example, after the weld is complete, the automatic tool changer can quickly swap the pin tool for a flash removal tool - no need to move to another machine.
2. Zero-Point Locator System: Located along the X-axis of the machine, the zero-point locator system enables automatic tooling position fixing and clamping in one step, reducing setup times by up to 90% and improving accuracy with minimal effort.
3. Rotating Head: Allows tilting about the A axis ±91°, accommodating for complex geometries to be joined with ease, enhancing versatility.
The FS-1 is perfect for a wide range of applications, including...
- Cold Plates
- Heat Exchangers
- Battery Casings
- Electronic Enclosures
- Aluminium Extrusions
Why MTI?
MTI offers comprehensive Friction Stir Welding solutions out of our Manufacturing Services facility in the U.S., from prototyping to full-scale production. Our dual-sided welding capability and ability to join components up to 53 feet in length set us apart in the industry.
In addition to FSW, we also offer Rotary, Low Force, and Linear friction welding for both contract production and machine builds! Our Manufacturing Services facilities also include value-added services such as pre and post-weld processing, an on-site metallurgical lab, and part design aid - all aimed at delivering the highest quality and efficiency for your projects.
Getting Started
With added capacity and an eager team, MTI is ready to take on your toughest welding challenges. Have a few questions? Let our team of experts take it from here.
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