What is Friction Stir Welding? | FSW for DUMMIES

Hey everyone! In this video, learn what Friction Stir Welding is in the easiest way.
Download now for FREE my white paper about FSW principles and trends: bit.ly/3Vu16qZ
👉 So, what is FSW? Friction Stir Welding is a solid-state joining process that uses a non-consumable tool to join workpieces without melting the material. This technique is very efficient for welding aluminum components. It’s also possible to weld materials like copper and steel, and even make dissimilar assemblies.
In this video we cover:
🎥 We’re welding two metal plates with a Friction Stir Welding head in a CNC machine. We will explain and show the basic principles of FSW and then conduct a bending test of the weld to assess its resistance.
👉 Why is FSW important? It's because FSW produces high-quality welds with low distortion and no need for filler materials. It’s also possible to weld materials like copper and steel, and even make dissimilar assemblies, which are combinations of different metals. FSW is widely used in aerospace, automotive, and shipbuilding industries due to its strength and reliability.
If you've ever been curious or you're just starting out in the world of manufacturing, you've come to the right place!
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• Learn more by watching the free replay of one of our webinars about “
All you need to know about Friction Stir Welding” : • WEBINAR FSW Unveiled: ...
Chapters:
00:00 Introduction
00:14 Friction Stir Welding tool
00:31 Clamping
00:49 Starting FSW process
01:39 Result of the joining
01:45 Bending test of the part
02:17 Applications & parts presentation
02:38 Outroduction
#FrictionStirWelding #Aluminumweling #Welding #Weldingmachine #Stirweld #FSW

[@blchandl2]

I developed a friction stir welding process over 14 years ago for automotive applications including sealing electronic enclosures and cooling applications for power inverters (similar to the example in this video). It was one of the most interesting projects I ever worked on.

[@carlhumphreys9024]

Friction Stir Welding is very impressive. I subscribed and gave a 👍up.

[@gags730]

Please lower the music in future videos or get rid of it all together. It is hard to hear you clearly, especially with the music. That was a good demonstration... TY

[@Stirweld]

Noted for next time. Thanks for your feedback.

[@pol4375]

Pas besoin de parler anglais pour voir que vous êtes français ! 😂 c'est excellent c'est une vrai solution, qui peut être utile dans énormément d'usage. On pourrais même amélioré ce processus (je penses) avec une températureplus élevée, pour ne pas donner une contrainte trop forte sur la broche. Pensant que votre CN est tout d'abord d'usage classique (type usinage).

[@Stirweld]

Oui, nous sommes Français et utilisons l'Anglais pour rendre accessible cette technologie au plus grand nombre. Et effectivement la machine que vous pouvez voir dans la vidéo est une machine d'usinage classique avec notre tête de soudage FSW intégrée qui permet de faire du soudage par friction malaxe, rendant votre CNC totalement hybdride !

[@pol4375]

Oui j'ai bien reconnu vos CN HAAS... bonnes machines. Est ce que vous travaillez pour des particuliers ? Pour des usagers professionnelles, voulant faire un travail à titre "personnel"...

[@PiDsPagePrototypes]

It's going to be interesting to see if this works better in Low Earth Orbit then traditional stick welding techniques. It appears you did Aluminium in the example, what was the tool tip made from? What is the hardest metal the method can weld?

[@JH-zo5gk]

Is there 3d stir welding? Such as the tubing on a roll cage or something like that?

[@danhammond8406]

Ditch the music please

[@philcook9967]

Great video, lose the music

[@stellablaze7979]

I don't mind it at all. Personal preference for sure

[@Tevon93]

The music doesn’t belong in a video like this. This isn’t a TikTok

[@user-sc9qm2md4d]

What would be the challenges with FSW mitered tube joints, such as a bike frame in 7075? Too thin tube walls + need for 4 or 5 axis machine?

[@Stirweld]

For more specific requests, such as your project, I encourage you to contact us via this link: bit.ly/3xeK06O ☺

[@drive-channel1834]

Yea, ditch the *noise* (some people call it "music") please

[@johnwarwick4105]

That’s insane 😳

[@haethimheyjazii729]

does friction stir welding steel or titanium require a tool that is made of a harder carbide?

[@Stirweld]

Yes, FSW of steel requires specific FSW tools with high strength materials and its applications remain limited. Regarding titanium, it is not yet FSWeldable.

[@Eli-lt2vo]

Boeing has developed a titanium FSW method for joining panels for superplastic forming

[@vitalic_drms]

jesus, I’ve seen what you do with stir friction welding and I want that for me

[@wellscampbell9858]

Looks like it's best suited for high part count production. Making a dedicated jig for one-offs or short runs would be expensive. I'd like to see the bend test go the other way, so that the backside is put in tension. For that matter I'm curious why you didn't show the backside at all. Also looks like taking the seam to the edge is problematic.

[@Stirweld]

You are right, FSW is relevant for large batches or high added-value parts. We welded in partial penetration in this video, just for easy demonstration : feel free to contact us if you want to get full penetration and successful root bending examples. The tool must plunge and rise vertically, so run-in/run-out strips can be needed for edges management on the applications that requires it.

[@amitaimedan]

Interesting, but how does it work? I see no heat.

[@Stirweld]

It's normal; Friction Stir Welding doesn't reach the material's melting point. It's a "cold" welding process. The temperature initiated by the rotating FSW tool is high enough to soften the aluminum but not make it liquid, allowing the material to be joined together without melting. 😉

[@Iowa599]

How can I do that with a hand drill?

[@blchandl2]

You need several hundred pounds of down force while moving the bit through the weld path.

[@Iowa599]

@@blchandl2 so about an inch (~2.5cm), then the drill bearings will also be welded.

[@blchandl2]

@@Iowa599 LOL probably. It also takes several hundred pounds of lateral force to move the weld tool through the material. Take notice of the wobble as the bit is driven into the plates at the start of the video.

[@dustinandtarynwolfe5540]

There are better processes for the time it takes and outcome. Laser welding is the future. This is niche market at best

[@anzaklaynimation]

15000 people were dummy.😂😂

[@tomg6284]

Music sucks.