Frictional heat creates perfect joints

 

Wear-resistant tools create frictional heat and exert pressure on the joining area. The fixing of the components and a solid base ensure that the horizontal and vertical process forces are absorbed.

The friction between the rotating tool and the material gives rise to the heat necessary for plasticization.

The tool is moved along the joining area and stirs the plasticized material in the interior of the seam.

The applied force presses the material together. At the end of the seam, the tool is withdrawn from the joining area. The weld seam is immediately fit to withstand normal use.

What can be joined:

  • Friction stir welding can join workpieces at butt joints, lap joints or right angles (T-joints) and also enable a wide variety of joining combinations.
  • The process can also firmly bond multi-material joints and different materials with one another. Examples include Al-Mg joints, Al-Cu joints and Al-steel joints.
  • We weld, among other things, materials produced by means of different production processes, such as cast and sheet metals, as well as different sheet thicknesses, as is the case with tailored blanks.
  • Curved and three-dimensional seams can be joined by RIFTEC using appropriate plant technology.
  • High welding speeds can be achieved above all with thin sheet metals.

The quality you can expect:

  • Friction stir welded joints display even, regular surfaces.
  • They stand out by virtue of their comparatively low distortion and high fatigue strength. This applies to deformation and to fracture-mechanical influences. And the seam area still can be formed with outstanding results.

Selected examples from our everyday practice

Butt Weld EN AW-5754 H111

Material thickness 1.5 mm
Welding speed 1,500 mm/min

Yield strenght
[MPa]

Tensile Strength [MPa]

A [%]

* Average out of three specimen

Base material

115

240

26.6

Friction stir weld*

120

245

21.1

Joint efficiency

1.04

1.02

0.79

Rupture location

Base material

Bend test

180° Bend angle for face and root side without failure

Tailored Blank EN AW-6181 T4

Material thickness 1.1 / 2.5 mm
Welding speed 1,250 mm/min

Yield strenght
[MPa]

Tensile Strength [MPa]

A [%]

* Average out of three specimen

Base material

125

275

16

Friction stir weld*

146

301

24.7

Joint efficiency

1.17

1.09

-

Rupture location

Thinner base material

Bend test

180° Bend angle for face and root side without failure

Butt Weld EN AW-7075 T651

Material thickness 3.4 mm
Welding speed 450 mm/min

Yield strenght
[MPa]

Tensile Strength [MPa]

A [%]

* Average out of three specimen
** according to material specification

Base material**

-

540

-

Friction stir weld*

313

504

9.7

Joint efficiency

-

0.93

-

Rupture location

Heat affected zone

Bend test

Bend angle for face and root side without failure