Friction Stir Welding (FSW) is a solid state welding process

• First discovered and patented by The Welding Institute of Cambridge U.K. in 1991
• First production use in USA was in 1998 for The Boeing Company on Delta Launch Vehicle

Steps of the Process:

• The process uses a rotating, non-consumable weld tool that plunges into the base material and moves forward
• Frictional heat caused by the rotating pin creates a plasticized tubular shaft around the pin
• Pressure provided by the weld tool forces the plasticized material to the back of the pin, cooling and consolidating

Typical Weld Tool Profile

Process Highlights

• No melting occurs during welding
• Welds all aluminum alloys
• Increased weld strength over fusion welding
• Fatigue resistance
• Corrosion resistance
• Reduced distortion over fusion welding
• No consumables used
• No shielding gasses required
• Repeatable
• No environmental impact
• Increases energy savings
• Reduces inventory