Friction Stir Welding at TWI Yorkshire

The development of TWI's friction stir welding facilities has always been a key part of the company's expansion in the South Yorkshire region, and this has been achieved through investment in two custom-built machines. These machines were selected to complement the comprehensive suite of friction welding equipment already available at the Cambridge site and bring the total number of friction stir machines available at TWI to 9.

• Capabilities
• Case Studies
  • Successful welding of thick section magnesium
  • Warming to Friction Stir Welding - how a Leeds based company explored the use for FSW in its manufacturing process.
• Further Information

TWI Yorkshire FSW Capabilities

High Force Multi Axis FSW machine

This machine was selected to extend the boundaries in the research and development of thick section FSW. The machine is one of the largest FSW machines in the world with over 130KW of spindle power. It has 12 programmable machine axes, a maximum down force of 15 tonnes and operates over an area of 6m x 3m. The machine has 3D welding capability and features an opposed welding head - a second welding head located directly beneath the upper head, which allows simultaneous, twin-sided welding to be performed. This offers the potential to weld materials up to 100mm thick in one pass.

Precision Spindle FSW Machine

The unique feature of the machine is its high concentricity spindle. This precision spindle allows research into the new range of ceramic tools being developed for friction stir welding of materials which have higher softening temperatures than those metals traditionally welded by FSW. Higher softening temperature materials include steels, stainless steels, titanium and nickel-based alloys.

This fully instrumented machine is capable of producing a down force of 10 tonnes and has a working envelope of 2m x 0.6m

RoboStir Robotic FSW Machine

This system combines the power of friction stir welding technology with the flexibility of a robot. This provides versatility not before associated with friction stir welding, with the ability to weld in any position and follow complex 3D weld paths, with the possibilities only limited by the imagination of the engineer.

The machine has a working envelope of 5 metre diameter and can be physically repositioned to cater for larger components.

The system incorporates a comprehensive data logging system to monitor and control the important FSW process parameter.

The robot will also provide the platform to develop the variant of FSW, Friction Spot Stir Welding which is solid state welding alterative to conventional spot welding.

For more information about TWI's friction stir welding activities, please contact jonathan.martin@twi.co.uk, or follow the links below:

• Friction stir welding at TWI
• Simultaneous use of two or more friction stir welding tools
• Friction stir welders provide prefabricated components and panels
• Stirring things up on London's rail network
• Friction stir welding in series production
• Pushing the boundaries - Friction stir goes deeper than before
• Causing a stir in the welding world