What is the Advantage and Disadvantage of robotic friction stir welding

Jul. 14, 2025

FAQs - Stirweld

What are the main applications of FSW in energy sector industry?

Friction stir welding (FSW) has found many applications in the advanced energy sector. The FSW process is used for the manufacture of heat exchangers such as lamellar exchangers or plate heat exchangers. In the wind industry, FSW has become a…

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Do we need to have clearance from te CNC manufacturer to implement the FSW head?

No, you do not need permission to mount an FSW head on your machining centre. Stirweld’s welding head is universal and can be easily installed on any type of CNC. The FSW head behaves like a module added to your…

Why is Aluminium not welded?

Yes, but some families of alloys are not weldable: 2xxx and 7xxx due to their high sensitivity to cracking. Moreover, this light metal must be welded with care so that the parts do not deform. Friction stir welding (FSW) is…

What is the strong of friction stir welding?

The welding force is the pressure exerted by the robot or the machine during friction stir welding operations. The force control is one of the most important elements for a quality FSW weld. The friction stir welding force is measured…

How to manage the force with the FSW head during FSW operations?

A constant force of the FSW tool on the parts to be joined is essential to guarantee a quality weld. For this reason, Stirweld has integrated a force sensor into its FSW welding head. This feature monitors the pressure exerted…

What types of aluminium can be welded by FSW?

FSW can be used to weld all aluminium alloys, including those that are not weldable with conventional processes. With this process, it is now possible to join high-strength aluminium alloys such as the , and series. FSW is…

How to fill the exit hole of the FSW welded material?

An exit hole is left by the FSW tool during the removal phase. This hole at the end of the bead has no impact on the quality of the weld. It can be prohibitive for certain applications of circular welds…

What is a pin tool in friction stir welding?

The FSW tool pin is one of the components of our friction stir welding tools. It is located at the end of the tool in the extension of the shoulder. The length of the FSW tool pin depends on the…

In FSW, a wormhole is it similar as the tunnel effect?

Yes, a wormhole is a FSW defect also called a tunnel in friction stir welding jargon. Identifiable to the naked eye, this weld defect is characterised by porosity along the weld joint. The wormhole is a defect that can occur…

How do you check for welding defects?

The quality of FSW welds can be verified by non-destructive testing (NDT) and destructive testing to ensure compliance with the FSW ISO standard. The visual inspection permits the observation of visible defects to the naked eye which appear as…

Can we use same tool to weld copper and aluminum?

No, it is important to use an FSW tool that is suitable for the material being welded. Copper and aluminium react differently to heat during the welding process. If the temperature is too high, copper will tend to stick while…

Is your FSW equipment able to weld 3D double-curvature structures ?

Yes, Stirweld’s FSW robot spindle can weld structures with complex geometry such as double curvature. Our Robotic Friction Stir Welding technology has made complex path welding operations possible. This multi-directional welding capability has opened up opportunities for advanced industry sectors…

What about lap weld by FSW?

In this FSW configuration, the parts to be joined are positioned one on top of the other. This joint geometry allows for the positioning of dissimilar materials or parts with different thicknesses to be avoided. The FSW process keeps the…

Could FSW process used to link aluminum thick sheets in production line?

Yes, the friction stir welding process can be used to join thick aluminium alloys. Our FSW welding head allows access to quality welds up to 20 millimetres thick of the base material.

What is the best way to weld Aluminium?

Welding aluminium is a much more complex operation than for other metals. Welding aluminium requires a great deal of skill and the right tools. The best way to weld aluminium is by cold welding, or more precisely, by welding in…

What is tunnel/wormhole defect in FSW?

Wormhole is a defect that can be encountered in friction stir welding (FSW). It can occur on FSW butt or lap welds. Visible to the naked eye, the wormhole is an internal cavity in the welded joint. This porosity is…

Is your FSW head regulated by force?

Yes, the Stirweld welding head is force controlled. The pressure exerted on the workpiece must be constant in order to guarantee quality FSW welds. It is therefore essential to know and control the force to be applied during the FSW…

What are the advantages and disadvantages of friction stir welding?

FSW technology offers many technical and ecological advantages. Green welding technology, it does not involve any fusion or addition of material. It does not emit toxic gases or UV radiation. Energy consumption is reduced compared to other welding techniques (TIG,…

What does FSW mean in welding?

FSW stands for Friction Stir Welding. Invented in by The Welding Institute (TWI), the FSW process is based on the assembly of two parts by heating the materials. The pasty state is obtained thanks to the friction of a…

What are the main applications of FSW in aeronautics industry?

Friction stir welding (FSW) is a welding technique that has been democratized in the aeronautical sector. The FSW offers the ability to weld large or complex panels such as wedi hull plates. It also provides a robust and reliable alternative…

How to manage temperature with the FSW head during FSW operations?

The welding temperature with the FSW head is managed according to 3 parameters: the feed speed: the faster the FSW tool feeds, the colder the material will be the rotation speed: the faster the tool rotates, the hotter the material…

What are the main applications of FSW in automotive industry?

The automotive industry uses the FSW process on an industrial scale for the construction of lighter vehicles. FSW technology allows the manufacture of light alloy components such as alloy wheels, body sheets, engine blocks or fuel tanks. One of the…

How to manage the clamping on big panels ? on a conventional machine ?

Clamping has an important impact on the quality of welds, for example on large panels from machine tools. The two parts to be joined must be clamped tightly on a support in order to withstand the welding forces. The clamping…

What is the maximum thickness in friction stir welding ?

The FSW head provides a quality single pass weld for parts up to 10mm thick. Our FSW technology allows a welding capacity of up to 20 mm with a double pass on both sides. This thickness also depends on the…

Is it possible to weld bimateriel parts? (alumnium with steel, aluminium with copper…)

Yes, it is possible to make welds with dissimilar materials using the FSW process. Friction stir welding is a breakthrough technology for joining different metals without melting or adding material. The FSW process allows parts to be welded together even…

What are the main applications of FSW in rail industry?

FSW technology allows the assembly of long panels, bent or folded parts or hollow sections. Therefore, friction stir welding has many applications in the railway field. In the context of the construction of high-speed trains, the FSW process is used…

Is cold welding real?

Yes, it is possible to weld in a cold or, more precisely, in a pasty state. This process is based on the joining of two materials in a solid state without exceeding the melting temperature. Cold welding is used in…

What are the types of welding processes?

There are many welding processes that apply to different jobs and work environments. The most common welding processes are: •,Coated electrode welding, more commonly known as arc welding or MMA •,TIG welding, performed with gas arc with tungsten electrode •,MIG…

What is flash defect in FSW?

In welding, flash refers to the burr on the retreating side due to the rotation of FSW tool. The flash is the main defect that can be encountered during a friction stir welding operation. Flashes occur mainly when too much…

What are the main applications of FSW in aerospace industry?

Friction stir welding has many applications in the aerospace industry. Indeed, this sector has adopted FSW, which makes it possible to weld all aluminum alloys One of the main aerospace applications is the assembly of aluminum hydrogen tanks. FSW provides…

How do I know if my weld is strong enough?

In order to ensure the solidity of your weld, it must meet two essential conditions: the right penetration of the weld and homogeneity along the whole length. For maximum strength, it is necessary that the parts are fully penetrated. The…

What are the main applications of FSW in navy industry?

Friction stir welding is applied to the manufacture of large aluminum floors for naval structures. The FSW process also allows the production of high-strength extruded aluminum decks and bulkheads, alloys that were previously considered un-weldable. Finally, FSW has become an…

What is the friction stir welding process?

Friction stir welding is a solid state welding process without the need for filler metal. This technique is more commonly known as FSW for Friction Stir Welding. This breakthrough technology was invented and patented in by The Welding Institute…

What is the benefit of adding force control to a machine tool?

The machining centre is designed to operate in position control. Friction stir welding requires force control, and therefore a force sensor to control the friction of the shoulder on the workpieces. Integrated directly into the Stirweld head, this sensor measures…

What are the common weld defects?

There are 5 main FSW defects: Flash or burr on the edges of the weld ; Wormhole or tunnel which i.e. a porosity present on all or part of the length of the weld ; Lack of penetration which is…

What is the difference between friction welding and friction stir welding?

Friction welding (or inertial friction welding) is a process where the heat required for welding is obtained by rubbing the parts to be joined together under axial pressure. Friction stir welding (FSW) is a variant of friction welding. FSW is…

How effective is friction stir welding?

The effectiveness of friction stir welding is particularly well known for joining materials identified as difficult to weld, such as aluminium. Friction stir welding technology can be used to weld all aluminum alloys. FSW welding of the series retains…

Is the FSW tool the same for lap and butt welding?

Yes, the FSW tool is the same regardless of the welding configuration (lap or butt). The choice of the tool depends on the distance to be welded, the depth to be welded and therefore the thickness of the part and…

Can we make the milling operation without making dissasembly of the head?

Yes, it is possible to switch from welding to machining and back again without disassembling the FSW head. The Stirweld welding head was designed by experts in FSW and machining. This hybrid system allows welding and machining to take place…

What degree of tilt is acheived with FSW head?

Our FSW tool does not require tilting to ensure a solid weld. When using our FSW head on a 5-axis machine, tilting can be done. The degree of tilt of the Stirweld FSW welding head is between 0.5° and 3°.…

How can I assure the quality of my FSW weld?

In order to guarantee the quality of a FSW weld, it is necessary to carry out a study of prototypes in accordance with the ISO standard. These prototypes are controlled by destructive and non-destructive tests. Non-destructive testing (NDT) includes…

WPS certificate – Is it general for all FSW parts or application specific?

The WPS (Welding Procedure Standard) certification is valid for a specific application. It depends on the material, its thickness and the welding configuration. For each application, it is therefore necessary to qualify the weld according to these parameters. The WPS…

Can the FSW technique be used even if the tool is not correctly inclined when moving along the weld?

Yes, it is no longer necessary to tilt the tool during the FSW process with our technology. Other friction welding processes will require a tool tilt angle to be set to improve the surface finish of the joints. The purpose…

What is hooking defect in FSW?

Hooking is a defect in the surface of the material that can occur in FSW welding operations. The material rises on the edges of the feed zone and it thins on the receding side. This internal defect can be detected…

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What about T-Joint by FSW?

In butt and through welds configurations, there are several ways to position the parts to be joined. The T-joint is one of them. FSW T-joint welding is achieved by intersecting the two parts at right angles with one part in…

Do you develop and manufacture specific tools?

Yes, Stirweld offers the development of custom FSW tools to suit the specific needs of our customers. We also offer a wide range of standard FSW tools available in our catalog. We study the customer’s request and help him to…

What are the main applications of FSW in telecom industry?

Today, various areas of the telecommunications industry have adopted the FSW process for welding these aluminum and copper components. Friction stir welding optimizes the welding of machined cold plates for satellites and data centers. In addition, FSW technology coupled with…

How control the temperature of the tool during the process ?

Stirweld’s FSW solutions can be equipped with temperature measuring tools. Stirweld’s intelligent tool holder is simply installed on your welding heads and spindles. It allows to check that the heat is constant during the friction stir welding process. For quality…

Can you weld aluminum to steel?

Yes, it is possible to join aluminium and steel parts using recent welding processes, including friction stir welding The physical properties, coefficient of expansion and electrochemical potential of these two materials are very different. With conventional welding techniques, it is…

What kind of welder do I need to weld aluminum?

The qualification of the welding operator depends on the technology chosen to weld aluminium. It is possible to weld certain types of aluminium alloys with traditional welding processes such as TIG or MIG. These techniques require the welder to have…

Which welding is strongest?

Friction stir welding (FSW) guarantees a higher quality and strength of the welds than those obtained by conventional techniques (TIG, MIG, EBW). There are 2 types of FSW welding: butt or lap welding. The choice between these configurations depends on…

What about laser welding of the cover for a liquid cold plate?

Laser welding of aluminium, like electron beam welding, has porosity defects. However, cold plate welding requires a 100% seal. In addition, laser welding requires a smaller gap between the two parts. Friction stir welding is an innovative and popular technology…

What about the life of the tool? (in weld meter)

[et_pb_section][et_pb_row][et_pb_column type= »4_4″][et_pb_text] The average life of our tools is metres of weld in a typical FSW configuration. The life of the FSW tool varies depending on 2 key factors: the correct use of the tool and its settings. The…

What are the main applications of FSW in defense industry?

Friction stir welding provides an answer for optimal thermal management in the field of Defense. Liquid cold plates are used to cool embedded systems such as commercial radars or control and power electronics. Allowing the assembly of any type of…

Is the tool shoulder in contact with the workpiece surface during the FSW process?

Yes, in FSW welding, the shoulder must be in permanent contact with the surface of the workpiece. It is the friction of the shoulder against the workpiece that provides the heating necessary for the friction stir welding operation. The shoulder…

What are the advantages of using the FSW head with retractable pin?

The use of the FSW head with retractable pin offers the advantage of not leaving an exit hole unlike standard welding heads. As its name indicates, the pin retracts at the end of the weld. It allows to directly close…

How is friction stir welding done?

Friction stir welding (FSW) consists in assembling two parts by bringing them to a pasty state thanks to a rotating pin, in particular thanks to a robot or a FSW head for CNC. Specifically, the rotating tool is pressed into…

Can you weld aluminum to inox?

Yes, it is possible to join aluminium and stainless steel parts even though both materials are known to be difficult to weld. Unlike stainless steel, aluminium is a light metal that welds at low temperatures. Joining these materials with conventional…

What are the challenges of FSW 3D welding?

A 6-axis robot with an articulated arm equipped with an FSW spindle can weld in 3 dimensions. This equipment offers a wide range of movement allowing welding horizontally, vertically, on the ceiling… This multidirectional welding capability makes 3D welding of…

Can the FSW head machine and FSW?

Yes, Stirweld’s FSW welding head is a hybrid system that allows machining and welding. The FSW head fits all machine tools and is easily installed for an optimized friction stir welding operation. The user can quickly mount and dismount the…

What is friction stir welding used for?

Friction stir welding is a solid state welding technique that does not reach the melting point. Known for its ability to weld difficult to weld materials, FSW is mainly used for the high quality joining of aluminium and copper parts.…

Who invented friction stir welding?

Friction Stir Welding (FSW) was invented by Wayne Thomas of the Welding Institute in . The TWI is a British research and technology organization specializing in welding. In , a second patent was filed to extend the application to the…

What are the different applications that benefit from the FSW head with retractable pin?

Compared to a conventional FSW head, the FSW head with retractable pin has an additional function: the progressive removal of the pin in the shoulder in order to fill the exit hole of the FSW weld. As the only FSW…

Is it important to have access to force datas in production?

Yes, it is essential to get the welding force data during the operation. This information allows real-time control of the quality of the weld. Our FSW Stirweld heads and spindles are designed to provide this intelligent data through its powerful…

How deep is the tool inserted into the material?

The depth of tool penetration is one of the main parameters of the FSW process to ensure the quality of the weld. For this purpose, it is necessary to carry out prototype tests in order to define the welding parameters…

Can you weld aluminium to copper?

Yes, it is possible to join aluminium and copper parts even though these materials have different physical characteristics. Welding aluminium with copper allows, among other things, to limit the electrical resistivity of the latter. FSW is therefore used in cold…

What is lack of penetration defect in FSW?

Lack of Penetration (LoP) occurs when the metal does not completely fill the thickness of the joint. This internal defect can occur during butt welding operations. This lack of root penetration is mainly due to the fact that the pin…

What are the different FSW weld types?

The most common types of friction stir welding are butt and lap welding. The most usual FSW configuration is butt welding. The parts to be joined, of equal thickness, are placed against each other. In a lap weld, the two…

Is any pre-heating required or recommended before commencing the welding process?

No, external preheating is not necessary for a welding operation with FSW technology. We have integrated a delay phase into our welding process that avoids this phase. The preheating action is thus carried out by the tool itself while continuing…

What about butt weld by FSW?

FSW butt welding involves joining parts together tightly so as to limit the thickness of the joint. The rotating FSW tool is brought into contact with the materials to be joined. The material is softened by the heating action of…

How to control the distoration when you only weld from one side?

During an FSW welding operation, the shoulder brings heat to the top of the workpieces to be welded. This can cause distortion of the material which requires post-weld machining to restore the correct flatness. To control this distortion during friction…

What is the best grade of aluminum to weld?

The , and series, which are not heat treated, are the easiest aluminium alloys to weld. The series is also easily weldable. However, depending on the welding technique, the joining process may cause a decrease in the…

If weld has defect like worm hole or kissing bond how to repair it?

A friction stir weld may have wormhole or kissing bond defects. In order to repair these defects, it is necessary to pass the FSW tool over the weld again. In the case of a wormhole defect, the welding operation must…

Friction stir welding VS traditional methods I TRA-C Industrie

In engineering and metallurgy, the welding process plays an essential role. TIG/MIG welding, gas welding, resistance welding, ultrasonic welding: many processes have been invented.

Friction stir welding (FSW) has revolutionised the traditional approach to welding. As a reliable, innovative and environmentally-friendly technique, what sets it apart from other methods?

In this article, TRA-C industrie takes a look at this technology, as well as more conventional techniques. You will also discover the advantages of friction stir welding over other processes…

Friction stir welding is a relatively recent innovation in the field of mechanics and welding. Invented by Wayne Thomas and developed by The Welding Institute (TWI) in the UK, the process was introduced in .

This technique offers a solution to problems commonly encountered with more traditional welding methods such as:

Distortion
Cracks
Degradation of steel mechanical properties

Since its development, friction stir welding has been used in many industrial sectors, including aerospace, automotive and shipbuilding. Its advantages in terms of weld quality, cost and durability are now well established.

This technique has also been the subject of a considerable amount of engineering research and development. These advances have led to significant improvements and a wider range of applications…

Friction stir welding is a solid-state welding process that is particularly effective for welding aluminium, light or multi-material alloys (aluminium-copper, aluminium-steel, etc.).

This process involves the use of a rotating tool, pressed against the parts to be welded. The friction generated by the movement of the tool produces heat, which causes the materials to soften and become malleable.
The tool is then moved along the joint, kneading the materials together to form a weld.

Although relatively new, FSW technology has already been the subject of a large number of research and innovation. For example, stronger and more durable welding tools have been developed.

As mentioned above, friction stir welding makes it possible to assemble aluminium alloys or very thick elements. This is much more difficult with traditional welding methods.

Another innovation in this sector is the precise monitoring of processes. Thanks to the machines used, everything is meticulously controlled, including temperature, pressure and tool speed. This improves the quality of the weld and reduces the risk of error.

FSW Also enables to use far less materials (weight saving) without altering the mechanical properties of the elements. It is used to assemble engine parts, heat exchangers, battery cases and alloy wheels, for example.

Finally, force control is a major innovation. In FSW, welding is carried out by applying constant pressure to the parts. The vertical position of the tool is then constantly adjusted to ensure that it is pressed against the workpiece and that the weld is homogeneous.

Electric arc fusion welding (TIG or MIG) uses electric current to produce heat and melt the materials to be welded. The energy required is obtained by an electric arc that is generated between an electrode and the part to be welded.
However, this technique is limited to electrically conductive materials and can lead to a deterioration in the quality of the weld. In addition, it requires a large amount of energy, which increases manufacturing costs.

Contact us to discuss your requirements of robotic friction stir welding(nl,cs,ms). Our experienced sales team can help you identify the options that best suit your needs.

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