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STIR WELD
In 1995, a new welding technique is invented by The Welding Institute (TWI): Friction Stir Welding (FSW). Since 2015, the TWI patent falls in the public domain, opening great opportunities for the development of FSW technology. FSW remains a technology reserved for high added value applications involving expensive equipment.
Our expertise, which is the result of many years of experience, enables StirWeld team to develop a technology for FSW on all types of NC machine tools. Around a skilled and fully involved team, StirWeld aspires to conquer a new market: FSW at low cost.
Technology
- Few consumables, no material input, no surface preparation, no shielding gas
- Welding of all aluminium alloys (1xxx, 2xxx, 4xxx, 5xxx, 6xxx, 7xxx)
- Al-Si: easy welding of aluminium foundry, including die casting
- No leakage: water, acid, or air
- Excellent thermal and electrical conduction.
- Solution to the shortage of qualified welders.
- Replacement of brazing, TIG, MIG or FE welding.
- Cold welding (temperature of 400°C): minimal distortion of welded parts
- No spar, no smoke, non-toxic.
- Already democratize in aeronautics, automotive, space, railway and naval sectors
- Existing welding standard: ISO 25239
- High mechanical resistance: weld efficiency of 80-90%, fatigue strength close to the base material
Application
FSW allows the assembly of aluminum profiles for rigid panel manufacturing:
- Thinner and wider panels
- One manufacturing step
- Lighter and more rigid panels
- Quality
Maturity:
This technology is already used in automotive (battery casing), rail (car blank), aeronautics and naval (floor)
For example:
Manufacture of heat sinks or other sealed system
關於STIR WELD
1991年，英國焊接學會 (TWI) 發明了一種新的焊接技術: 摩擦攪拌焊接 (FSW)。自2015年起，TWI的專利到期，為FSW技術的發展提供了巨大的契機。
STIR WELD在此領域擁有多年的經驗，透過其專業技術，開發出適用於所有NC類型的設備。
技術
- 低耗材、無需焊料、無需表面處理，無需保護氣體
- 可焊接所有鋁合金 (1xxx, 2xxx, 4xxx, 5xxx, 6xxx, 7xxx)
- 鋁-矽: 易於鑄鋁與壓鑄
- 無洩漏: 水，酸或空氣
- 出色的熱傳導與電傳導
- 解決焊工的短缺問題
- 取代硬焊、TIG、MIG或 FE
- 冷焊 (400°C): 減少焊件的變形量
- 無晶石、無煙塵、無有毒氣體
- 已廣泛應用於航空、汽車、航太、鐵路及造船業
- 焊接標準: ISO 25239
- 高機械阻力: 焊接效率為80%-90%，疲勞強度接近基礎材料
應用
鋁板材可利用FSW組合焊接，生產高剛性面板:
- 更薄、更寬的面板
- 僅一道製程
- 更輕、更堅固的面板
- 品質
已用於汽車(電池外殼)、火車(車體)、航太與船舶(甲板)
例如:
散熱器或其他密封連接系統
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FSW Head
“FSW head for NC machine tool: low investment cost, adaptability, ease of use and installation”
Our FSW head uses a NC machine tool for FSW. This innovation reduces drastically the investment cost to access to FSW while offering performances identical to a special FSW machine.
Advantages
- Low investment cost: Compared to FSW special machines or robotic stations
- Adaptability: Despite the lack of standard machining centers, the StirWeld FSW head can be adapted to all MOCNs.
- Ease of use and installation: After the first installation, the user can assemble and disassemble the FSW head in a few minutes from machining to welding and vice versa.
Head features
- Matching on 3 to 5 axis CNC machine
- Assembly or disassembly in 15 mins
- No hard or soft change of CNC machine
- Force control to secure the weld quality from 1 to 18 kN
- Water and air pressure cooling
- From welding to machining without head disassembly
- Small size to accomodate welding jig
- Self-lubricating: no maintenance
- CNC machine protection against the high forces (up to 18 kN) and vibrations duringthe FSW process
- Quick tool change (attachment with accurate positioning)
| Technical sheet | |
Size |
Compliant part: height of 300 mm |
| Interface: height from 60 to 110 mm depending on CNC machine | |
| Weight | 30 Kg |
| Water cooling | 5 l/min at 25°C |
| Air pressure cooling | 3 bar |
| Head | console distance up to 10m (more in option) |
Control Interface
- Recording of forging force for quality control
- Temperature monitoring for safe use
- Real time display process ajustment or process control
FSW 攪拌頭
“適用於NC設備的FSW攪拌頭: 低成本、高適應性、易安裝及操作。”
STIR WELD摩擦攪拌頭採用NC設備來進行摩擦攪拌焊接。此一創新相較於FSW專用機投入的成本低，但焊接效果是一樣的。
優勢
- 低成本: 相較FSW專用機或機械手臂焊接成本低
- 高適應性: STIR WELD摩擦攪拌頭可安裝於所有的立式加工機上
- 易安裝及操作: 首次安裝完成後，使用者可在幾分鐘之內快速安裝 / 拆卸STIR WELD摩擦攪拌頭。
攪拌頭特徵
- 適用於3~5軸的CNC設備
- 15分鐘內快速安裝或拆卸
- 可控制力流1~18 kN以確保焊接品質
- 水冷及氣冷
- 從焊接到銑削無需拆卸摩擦攪拌頭
- 自動潤滑: 無需保養
- 力流控制 (1~18 kN) 可在摩擦攪拌焊製程中保護CNC設備及避免震動
- 快速更換刀把
| 規格表 | |
尺寸 |
介面下方配件高度: 300 mm |
| 介面高度: 60-110 mm，取決於CNC機台 | |
| 重量 | 30 Kgs |
| 冷卻液: | 5 l/min (25°C) |
| 氣壓冷卻 | 3 bar |
| 摩擦攪拌頭傳輸線長度可達10米 | (若需更長距離請和我們聯繫) |
控制介面
- 力流歷程紀錄
- 溫度監測
- 即時回饋
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FSW Tools
“FSW Stirweld tools are robust and powerful at a controlled cost.”
For FSW, the weld quality depends on geometry and quality of the tool.
Our goal is to provide you a solution for every type of parts and materials. The tool selection has a direct impact on its wear and on the weld quality. Thanks to the FSW experience of its team, we offers you the most suitable tool for you use by combining quality, price and reliability.
FSW Tools Structure
The FSW tool consists of a shoulder to warm the material by friction and a pawn to stir the components. These two parts are essential elements to guarantee the good mixing of the material and the seamless welding.
The strong stirring of the material by the pin and the heat generated by the shoulder cause a phenomenon of recrystallization of the aluminum. This results in the precipitation of fine grains that will contribute to the very good mechanical strength of FSW welds.
Our tools can weld all part configurations
- Butt (similar or dissimilar thicknesses)
- Transparency
- T-shaped (or welded at an internal angle through the top)
Discover our range
| High strenght Aluminium Alloys | ||
|---|---|---|
| Thickness to weld | Welding type | Tool ref |
| 1 to 2 mm | butt, overlap,,T-shap | F-HSA-1-X |
| 2.1 to 4 mm | butt, overlap,,T-shap | F-HSA-2-X |
| 4.1 to 6 mm | butt, overlap,,T-shap | F-HSA-3-X |
| 6.1 to 8 mm | butt, overlap,,T-shap | F-HSA-4-X |
| 8.1 to 12 mm | butt, overlap,,T-shap | F-HSA-5-X |
| 12.1 to 16 mm | butt, overlap,,T-shap | F-HSA-6-X |
| 16.1 to 25 mm | butt, overlap,,T-shap | F-HSA-7-X |
| Standard AI-AI Tools | ||
|---|---|---|
| Thickness to weld | Welding type | Tool ref |
| 1 to 2 mm | butt, overlap,,T-shap | F-AA-1-X |
| 2.1 to 4 mm | butt, overlap,,T-shap | F-AA-2-X |
| 4.1 to 6 mm | butt, overlap,,T-shap | F-AA-3-X |
| 6.1 to 8 mm | butt, overlap,,T-shap | F-AA-4-X |
| 8.1 to 12 mm | butt, overlap,,T-shap | F-AA-5-X |
| 12.1 to 16 mm | butt, overlap,,T-shap | F-AA-6-X |
| 16.1 to 25 mm | butt, overlap,,T-shap | F-AA-7-X |
| AI-Si Tools | ||
|---|---|---|
| Thickness to weld | Welding type | Tool ref |
| 1 to 2 mm | butt, overlap,,T-shap | F-AS-1-X |
| 2.1 to 4 mm | butt, overlap,,T-shap | F-AS-2-X |
| 4.1 to 6 mm | butt, overlap,,T-shap | F-AS-3-X |
| 6.1 to 8 mm | butt, overlap,,T-shap | F-AS-4-X |
| 8.1 to 12 mm | butt, overlap,,T-shap | F-AS-5-X |
| 12.1 to 16 mm | butt, overlap,,T-shap | F-AS-6-X |
| 16.1 to 25 mm | butt, overlap,,T-shap | F-AS-7-X |
| Tool holder | ||
|---|---|---|
| Operation | Machine Type | Tool reference |
| FSW welding | Stirweld FSW head for NC machines | H-NC-W |
| FSW welding | FSW special machine | H-FSW-W |
| FSW welding | FSW Robot | H-R-W |
| Machining | tirweld FSW head for NC machines | H-NC-M |
| Machining | FSW special machine | H-FSW-M |
FSW on NC endurance bench test
Depending on the materials, we have developed FSW tools allowing a welding distance of more than 1500 m on all our Al / Al tools. We have designed a test bench to optimize the geometry of the tools. Tools and their heat treatment to meet these requirements.
Performance of our tools
The professionals at FSW Friction Stir Welding frequently encounter the following defects in their welding:
- Porosity continues along the weld (wormhole)
- Lack of penetration at the root of the weld
- Hang (typical defect of transparency welding)
- Burr on solder edges (flash)
We worked on the geometry of the tool to:
- Eliminate solder defects
- Maximize productivity (faster welding) thanks to the specific geometry of the tool
- Increase their lifespan
- Reduce effort on the tool to dramatically reduce damage from cyclic fatigue
- Optimize geometry and heat treatment to resist abrasive wear
Ease of use
We made the choice of standardizing attachments with the Whistle Notch system. This solution allows for quick insertion and removal of the tool. The axial position is guaranteed, the risk of damage to the housing when the tool change is canceled.
Discover in image below the simplicity of setting up our tools
FSW 刀具
“FSW刀具的優勢在於成本可控。”
對於摩擦攪拌焊，焊接的品質取決於刀具的幾何形狀與品質。
我們的目標是提供您任何形式與材料的解決方案。刀具的選擇會直接影響其磨損程度與焊接的品質。我們結合品質、價格和穩定性，以提供您最合適的刀把。
FSW刀把結構
FSW刀把的組成是利用刀肩摩擦材料產生熱以及刀頭攪拌材料。此兩部分是確保材料能完美混合以及無縫焊接的基本元素。
刀頭在強烈攪拌下與刀肩所產生的熱量導致鋁的再結晶現象，細晶粒的沉澱，使FSW焊接具有非常好的機械強度。
我們的FSW刀把可適用於所有焊接類型
- 對接 (相似或不同的厚度)
- 搭接
- T型焊接 (或頂部的內角焊接)
刀把類型如下
| High strenght Aluminium Alloys | ||
|---|---|---|
| Thickness to weld | Welding type | Tool ref |
| 1 to 2 mm | butt, overlap,,T-shap | F-HSA-1-X |
| 2.1 to 4 mm | butt, overlap,,T-shap | F-HSA-2-X |
| 4.1 to 6 mm | butt, overlap,,T-shap | F-HSA-3-X |
| 6.1 to 8 mm | butt, overlap,,T-shap | F-HSA-4-X |
| 8.1 to 12 mm | butt, overlap,,T-shap | F-HSA-5-X |
| 12.1 to 16 mm | butt, overlap,,T-shap | F-HSA-6-X |
| 16.1 to 25 mm | butt, overlap,,T-shap | F-HSA-7-X |
| Tool holder | ||
|---|---|---|
| Operation | Machine Type | Tool reference |
| FSW welding | Stirweld FSW head for NC machines | H-NC-W |
| FSW welding | FSW special machine | H-FSW-W |
| FSW welding | FSW Robot | H-R-W |
| Machining | tirweld FSW head for NC machines | H-NC-M |
| Machining | FSW special machine | H-FSW-M |
FSW在NC的測試
依據材質，我們設計了可允許焊接長度超過1500米的鋁對鋁刀把。 我們設計了測試台以優化刀把的幾何形態及熱處理，以達到這些需求。
刀把性能
摩擦攪拌焊接的專業人員在焊接過程中經常遇到以下缺陷:
- 焊縫有孔隙產生 (蟲洞)
- 焊接底部滲透不足
- 產生大量毛邊
我們致力於刀把幾何形式以達到 :
- 消除焊接缺陷
- 因特殊刀把的設計，可最大限度地提高生產效率 (更快的焊接)
- 延長刀具壽命
- 減少金屬疲乏對刀具的影響
- 優化刀把形狀及熱處理，以減少刀具磨耗
操作方便
我們選擇使用哨形凹槽刀把作為標準規格，可使刀把快速地被安裝與拆卸。軸向位置可被確保，避免主軸在刀具更換時受到傷害。
影片參考: