Friction Stir Welding

Friction Stir Welding (FSW) is a solid-state metal joining process producing high-strength, defect free joints in metallic materials. The process employs a pin tool with a low rotational speed and applied pressure that “mechanically stirs” two parent materials together to produce a uniform weld. 

It significantly reduces residual stresses and creates strong and flexible joints with low deformation, shrinkage and porosity. The process is fully automated and can be used for complex geometries.

NCAM has four PAR Systems machines for FSW; Universal Weld Systems #1 (UWS1), Universal Weld System #2 (UWS2), Robotic Weld Tool #3 (RWT3) and Process Development System #1 (PDS1).

photo: uwsi

Universal Weld System #1

Capacity

  • 16 ft x 21.5 ft x 10 ft of XYZ travels
  • 30 ft rotary table or 6 ft rotary table (table-on-table)
  • 7K lbs - X, Y & Z Loads
  • 2-axis gimbal weld head

Features

  • Large scale friction stir weld capability for complex geometries
  • Fixed pin and self-reacting pin tool capability allows for precise welding

 

 

photo: uws2

Universal Weld System #2

Capacity

  • 44.5 ft x 22.5 ft x 12 ft of XYZ travels
  • 22 ft rotary table & 22 ft T-Plate area
  • 40 ft x 20 ft flat weld area with T-slots
  • 5K lbs - X, 15K lbs - Y & Z Loads
  • 2-axis gimbal weld head

Features

  • Large scale friction stir weld capability for complex geometries
  • Fixed pin and self-reacting pin tool capability allows for precise welding 

 

photo: robotic weld tool

Robotic Weld Tool #3

Capacity

  • (3) 20 ft annular ring rotary tables, each with one rotational degree of freedom
  • 20 ft outer diameter, 15 ft inner diameter annular turntables with unlimited rotary motion and locking capabilit
  • Two columns, each with an independently operated weld head
  • 7 degrees-of-freedom (DOF) delivered through 5 physical axes
  • Work Envelope
  • X-axis Y-axis Z-axis
    93 ft 22-5 ft 12 ft

 

Features

  • Large scale friction stir weld capability for complex geometries
  • Fixed pin and self-reacting pin tool capability allows for precise welding

 

photo: pds1

Process Development System #1

Capacity

  • 40" x 120" x 24" of XYZ travels
  • Pitch = +/- 15 degrees
  • Roll = +/- 15 degrees
  • 0 – 3000 rpm
  • 10 T forge load (shoulder and pin)
  • Torque 3200 lbf-in (3000 PSI)
  • Torque 5500 lbf-in (5000 PSI)

Features

  • Precise position and load control
  • Fixed pin and self- reacting pin tool capability allows for precise welding