Friction stir welding (FSW)

Friction stir welding is the optimal joining process for non-ferrous metals with a low melting temperature and for mixed-metal combinations.

Friction stir welding (FSW): the process

Friction stir welding is a process in which a rotating pin is traversed along the contact surfaces between the workpieces. The frictional heat plasticizes the material, which is welded together.

The FSW process is particularly suitable for joining non-ferrous metals with a low melting temperature and for mixed-material joints. Even materials that are difficult to weld or dissimilar materials such as aluminium with magnesium, copper or steel can be friction stir welded.

Friction stir welding offers a number of advantages over conventional arc welding processes.

FSW ensures top weld quality
- No weld defects like pores or cracks
- Versatile material joining
- Comparatively low heat input
- High seam strength with minimal welding distortion
FSW guarantees cost-effectiveness
- Economical joining of complex 3D geometrie
- Material savings through component optimization
- No consumables like gas or filler
FSW ensures top weld quality
- Environmentally friendly thanks to low energy consumption
- No fume extraction or anti-glare measures required

Automated FSW process with robotic arm in electric vehicle production

Expert article

Friction stir welding as the optimal solution for modern battery housings

Industrial applications of friction stir welding

The Friction stir processing is used in various industries. The spectrum extends from the automotive industry, including the e-mobility market, and aerospace through to the electronics industry.

Friction Stir Welding for General industry
Economical welding of complex 3D seams, e.g. on cooling systems for power electronics or housings for cell phones

Cast components with aluminum sheets or sections

Welds with high conductivity for transformers and batteries

Joining of various material combinations – typically aluminium and its alloys, copper and magnesium alloys
Automotive industry
Economical welding of complex 3D seams, for example on parts of cooling systems, vehicle bodies and powertrains or e-mobility components

Joining of typical 4000/5000/6000 aluminum alloys and also hard-to-weld material combinations, e.g. aluminum sheets, continuously cast sections and cast components
E mobility automation
Friction Stir Welding for Aerospace industry
Welding of highly reliable, gas-tight seams, e.g. on aircraft fuselage parts and rocket components

Low heat distortion and special surface characteristics as well as material properties (e.g. tensile strength) at a very high level due to the low joining temperature

Typical materials: high-strength 2000 and 7000 series aluminum alloys
Rail vehicle construction
Joining of side walls and roof assemblies for high-speed trains and of aluminum sheets or sections (double-walled panels)

Highly economical joining thanks to FSW gantry systems and integration of additional machining processes such as milling and drilling

Typical materials: 6000 series aluminum alloys

Proven solutions: KUKA robots in use for FSW applications

Webinar-Special: Advanced Welding Solutions

Gain in-depth insights into rotary friction welding, friction stir welding, and magnetic arc welding in specific webinars.

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Friction stir welding in electric mobility – flexible and cost-efficient

In electromobility, friction stir welding has become firmly established among many OEMs and Tier 1 suppliers, particularly for welding battery housings for electric (EV) and hybrid (HEV) vehicles. The weld seams reliably meet the high requirements for tightness and crash resistance. Robot-based friction stir welding also offers high flexibility at comparatively low investment costs compared to conventional gantry systems. For the production of electric vehicles, KUKA offers a modular friction stir welding cell – a modern and economical solution that can be easily adapted to different production requirements.

KUKA cell4_FSW

Modular friction stir welding robot cell: the modern solution with low investment costs

Want customized solutions?

With our expertise and experience in welding, we would be happy to advise you and work with you to find the perfect solution for your specific welding requirements.

Perfect friction stir welding: from engineering to service

From feasibility and process investigations to trial welds, FSW tool selection and parameter optimization, including the conceptual design, manufacture and delivery of the system, KUKA offers the entire spectrum of services associated with friction stir welding.

Find out more about FSW Technologie here!

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Friction stir welding (FSW)

Friction stir welding (FSW): the process