Consulting/Development

For our understanding consulting is a form of art that bundles the knowledge and experience of people and supports them where it matters! ​

  • FSW basics according to ISO25239:2020

  • Fields of application and limitation

  • FSW materials (Al, St, Cu, Ti etc...)

  • FSW view in practice

  • FSW suitable seam design

  • Joint design

FSW Consulting

FSW trainings

 

Make our professionism to your benefit

Over the years we have gained a lot of experience in designing and layout the right FSW geometry. We would now like to share our knowledge with you in order to optimally design your components for later production. Our focus here is on the overall feasibility both in the production of e.g. cast parts and at the same time on the optimization of the joining zones in relation to the FSW process. It has been shown that the early involvement of our FSW experts can not only save time, but also avoid high costs in the subsequent production process. The optimized joint zone design means that a significantly higher welding speed can later be achieved, thus reducing the valuable cycle time. We also check the accessibility for the FSW tool and the necessary contact and support surfaces in order to minimize the risk of additional costs later on.

Our customers include well-known OEMs and Tier1 who use our expert knowledge to develop excellent and cost-optimized producible friction stir welded products!

Joint Design basics
FAQ's: commonly used FSW joint configuration

 

But Joint

FSW But Joint.jpg

Application: sheet metal, similar and dissimilar joints, tailor welded blanks

Advantage: strong connection, no crevice corrosion

Disadvantage: Machining is recommended to minimize gaps. Due to tolerances (gaps/high-low), more burrs are created

Lap Joint

FSW Lap Joint.jpg

Application: sheet metal, sheet metal and cast aluminium

Advantage: less burr, wide tolerances are possible, no seem preparation required

Disadvantage: crevice corrosion must be avoided

Lap Joint for Cast Aluminium

FSW Lap Joint Cast Aluminium.jpg

Application: cast aluminium and sheet metal

Advantage: less burr, wide tolerances are possible, no seem preparation required

Disadvantage: crevice corrosion must be avoided

Half Lap Joint

FSW Half Lap Joint.jpg

Application: cast aluminium and sheet metal

Advantage: no crevice corrosion

Disadvantage: seem preparation recommended, burr depending on tolerances (gap/ high-low), crevice corrosion on the inner side must be avoided

Application: cast aluminium (for example sheet metal lid on rips of a cast housing)

Advantage: less burr, wide tolerances are possible, no seem preparation required

Disadvantage: crevice corrosion must be avoided