When it comes to joining high-strength aluminum alloys, and other alloys that are difficult to weld by conventional methods, and ensuring that the joint maintains the full properties of the components being joined, the solution:
Rely on our experience and resolution.
The Friction Stir Welding (FSW) process offers many advantages over other arc welding processes:
We make this technology available to those who value its advantages with a process of progressive implementation and appropriate to each particular need.
Military tests on full penetration joining with Friction Stir Welding process. CJP
Welding on both sides of aluminum alloy up to 80 mm thick
Aluminum 15 mm thick being welded in both T-joint sides
1. Knowledge and y experience with FSW from its inception at close collaboration with TWI
2. Maintenance of the state of the art among continuous technology technology among alliances among developer companies of the process
3. Ability to study applications and solutions
4. Production capacity of prototypes and series of components
5. Capacity to design, manufacture and deliver production systems
6. Possibility of gradual implementation of welding technology for depreciation from the beginning of the solution to be adopted.
1. Technical knowledge
2. Experience in introducing new processes
3. Application and solution research capability with new technologies
4. Communication with the customer and understanding of their needs
5. Installation, commissioning and training
6. After-sales service
7. Maintaining state of the art
8. AWS Standardization for North American-influenced markets
We are not creating a need:
¡ We’re coming to cover an existing need !
–Process created, developed and patented by The Welding Institute (TWI) in 1991. The patent was made of public domain in 2015
Solid-state soldering process (joining temperature < melting temperature) without consumable input.
–The friction of the tool generates heat and molecular motion that allows welding
4 PROCESS PHASES:
TOOL – BOLT:
– Composed of a punch and a shoulder (pin and shoulder)
– The geometry is highly variable (cylindrical, conical, threaded, with flat recesses or grooves, with shoulder in the punch,…)
– The geometry of the bolt makes it possible to obtain a better mix of the materials to be joined
ESSENTIAL PARAMETERS:
-Rotation speed [RPM]
-Foward speed [mm/min]
-Perpendicular force [N]
5 zones differentiated in the weld
– Base metal: neither deformations nor heat modify its crystalline structure
– Heat Affected Zone (HAZ): no deformation due to the tool
– Thermo-Mechanical Affected Zone (TMAZ): is affected by heat and major plastic deformations. We see a rotation of the grains and the appearance of restoration and recrystallization phenomena
–Core: dissolution of precipitates, important deformations through which recrystallization occurs and new crystalline structures (small equiaxial grains)
Arm of Flow (Flow-arm): Recrystallized area, forged by the shoulder of the tool
Example of dissimilar joint Al-7XXX/6XXX:
Example of dissimilar joint Al-7XXX/6XXX:
TENSILE STRENGTH TEST |
The results of mechanical tests show that the properties of welds and thermally affected areas are very similar and sometimes superior to those of base metals with the FSW process |
Limitations
of the
processes
of
welding processes
at
arc welding processes
:
– Limited or not recommended weldability of some alloys.
– Limitation to weld some dissimilar materials
– Limited productivity
– Typical MIG defectology: porosity, lack of fusion, hot cracking, …
– Need for filler metals, with different composition and properties to base metals and with additional cost
– Reduction of mechanical properties of the joints of some alloys
– Distortion and residual stresses from contractions and dilations with high temperature variations
– Cost of changing wearable parts
Advantages of the process of welding Friction Stir Welding (8FSW) :
| ENVIRONMENTAL | FINANCIAL | TECHNOLOGY |
| No protective gas | Increased productivity (joining speed up to about 3 m/min) | It is possible to weld non-weldable or hard-to-weld alloys with conventional processes (series 2XXX, 7XXX …) |
| No smoke | Minimum consumable cost | Difficult or unweldable materials can be welded with fusion methods |
| No UV radiation | Tool life | Thick components can be joined, depending on the materials (50mm aluminum alloys with one pass, or 100 mm with one pass on each side) |
| Much lower temperatures | No addition of filler metal | It is possible to weld in many joint configurations: butt, overlap, T and edge |
 |
No beveling, even for large thicknesses of material to be joined | Avoids hot cracking and other defects, reduces distortion and residual stress, excellent repetitiveness and reproducibility |
We have automatic installations for welding components of different dimensions and in variable production quantity depending on the need.
These equipments are available for
Many materials can be joined with FSW process: Aluminum Alloys, Steel, Copper, Titanium, Nickel …
In addition, dissimilar materials can be joined, which is not always possible with traditional arc welding processes.
The following slides show applications of current productions in the fields of:
In summary :
The alliance TRA-C and Solysol-Arctech puts at your hand this technology so that your company decides in every step how integrating it of your own:
– Consulting on configuration of gaskets
– Design of components for the optimization of the production from product final product welded
– Production of prototypes for testing, qualifications y evaluation of costs y productivity
– Production of series while you evaluate the convenience of your investment in the equipment for your own production
– Transfer in full from all the technology y know-how obtained in the production for your company
– Implantation in your company of the equipment of production
– Advice during your first productions and for continuous improvements of the same components or new components to be welded with your equipment
– Integral after-sales service
