It’s a material whirl!

AMJune18Features - stirweld
AMJune18Features - stirweld

A French start-up company has developed a friction stir welding head that fits existing machining centres or NC machine tools to drastically reduce the cost of the technology. Aerospace Manufacturing reports.

Friction stir welding (FSW) is a promising technology for assembly of aluminium parts. All aluminium alloys can be welded, including 2000, 6000 and 7000 series high-strength alloys. This method is also used for assembly of dissimilar materials, such as aluminium-copper and aluminium-steel foundry parts. However, FSW remains a technology reserved for high added-value applications involving expensive equipment.

StirWeld, a young start-up company, has developed an FSW head that fits existing machining centres or NC machine tools. This makes FSW accessible by all the manufacturing companies, especially SMEs, as most jobshops are already equipped with NC machine tools. This new welding device requires only a few hours of training and becomes a true hybrid tool combining welding and machining. Moreover, this approach can save time as the components can be welded and machined in the same place, with the same machine. The system is suitable for small or large workpieces, with weld thickness lower than 15mm, which is sufficient for most applications.

StirWeld drastically reduces the cost of FSW technology while achieving performance identical to a special machine or FSW robot (force control, quality recording, etc.). StirWeld’s innovation enables companies to optimise their machines and implement new know-how for their customers.

The advantages of the FSW head for NC machine tools comprises low investment cost compared to special machines or robotic FSW stations as well as adaptability, indeed, StirWeld’s head can adapt to all NC machine tools. In addition, ease of use and installation means that after the first set-up, the user can load and unload the head within minutes, easily changing from welding to machining and vice-versa.

Today, Cap Group in Lisieux, France claims to be the first French subcontractor to offer this technology to its customers. StirWeld uses an NC machine tool for FSW, which reduces the investment cost of FSW while offering performances identical to a specialised FSW machine. This optimises the jobshop machines and diversifies their technology offer to customers.

For aluminium profile joining, the extrusion of aluminium parts is limited to a width of 500mm. However, FSW makes it possible to produce components whose dimensions aren’t achievable in a single extrusion.

When it comes to the replacement of traditional assembly methods, i.e. riveting, MIG welding and bonding, the most resistant aluminium alloys aren’t weldable with conventional technologies because of their chemical composition. These alloys are currently assembled by screwing, sticking or riveting. Many companies would like to replace these processes and reduce manufacturing costs while increasing the mechanical strength of assemblies. FSW results in fast and high strength assembly of all aluminium alloys and leads to perfectly sealed welds, resistant to high pressures. Moreover, FSW is very easy to implement, even for small batches and complex geometries.

When it comes to the welding of cast aluminium parts, these are difficult or not weldable with conventional processes, whereas FSW allows the welding of aluminium castings, even die-cast pieces, due to the solid state.

Another benefit is in the reduction of raw material. Many mechanical parts are machined from massive blocks of aluminium where up to 90% of material is removed. Many companies would like to reduce their raw material cost and machining time. The solution is to part weld by using FSW in order to get a preform as close as possible to the final shape.

FSW is also a replacement for lengthy spot welding as conventional resistance welding requires a finishing operation for ornamental applications. This operation is time-consuming and tedious requiring qualified operators. FSW by lap welding results in an unaffected reverse side and eliminates grinding.

Finally, for the welding of copper components, FSW replaces resistance welding or brazing by improving the junction quality, reducing the manufacturing cost (no electrode wear) and by increasing the mechanical resistance.

www.stirweld.com

Company

StirWeld

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