With extensive experience in a wide range of friction stir welding (FSW) applications and a strong background in system integration, our team offers in-depth capabilities to engineer and fabricate turn-key FSW systems. The supplied systems can perform some or all of the friction stir technologies (friction stir welding, friction stir processing, and friction stir spot welding). Friction Stir Link, Inc. (FSL) can provide both robotic based FSW solutions as well as custom engineered solutions. In addition, FSL can provide a variety of friction stir spot welding equipment solutions.


Robotic Friction Stir Welding System

For applications where productivity must be maximized or multi-dimensional welding is required, Friction Stir Link, Inc. has developed a robotic friction stir welding system, RoboStirTMWelding Cell. The system is based upon use of a high payload ABB IRB7600 Robot. The system is capable of welding material from 1 mm to 6 mm for most aluminum alloys, and up to 25 mm in thickness for 6xxx aluminum alloys. Friction Stir Link, Inc. has developed StirWareTM application software to allow the integrated system to perform friction stir welding (FSW), friction stir processing (FSP), and friction stir spot welding (FSSW). The software allows for force control capability and on-the-fly adjustment of welding parameters (force, position, etc.) to minimize setup time. The software also has the ability to automatically setup travel (tilt) and work angles required for the FSW process. Software options include data acquisition and force monitoring capability.

The system is a self-contained system with robot, platform, table, robot controller, and FSW controller, with an electric motor. The system has no hydraulics (no leaks and improved control). The system is available with force and torque sensing spindle and 5 kw motor. Optional equipment allow for increased motor power and multi-axis force sensing spindles.





For production applications, the system can be integrated with automated fixturing, PLC’s, fencing etc. Friction Stir Link has robotic systems in production and has used that expertise to develop production capable, robust, FSW systems. Robotic simulations of the production station (see below) are performed to estimate cycle times and perform interference analysis. The RoboStirTM system can also be integrated to tracks for panel welding applications (see below.


 


Friction Stir Spot Welding (FSSW) Equipment

For aluminum spot welding applications, Friction Stir Link, Inc. can provide a variety of spot welding systems. These systems are all based on the same control architecture, but vary in their mechanical integration. The three solutions are Robotic C-Frame Friction Stir Spot Welders, Bench-Top Solutions, and Press Type Solutions. The standard specification for all systems is:

1) All electric (no hydraulics)
2) Thrust force capability up to 25 kN (5000 lbs) at speeds up to 250 mm/s.
3) Rotary Power capability of 5 kW
4) Weld times of less than 0.75 seconds are possible (thickness and alloy dependent)
5) Minimum throat of 12”
6) Minimum depth of 8”
7) Device Net communication

Options Include:
1) Self-Clamping system, patent pending, used to eliminate need for clamping
2) Force and torque sensing spindles
3) Larger or smaller rotary motors
4) Larger or smaller thrust force capability
5) Increased or decreased throat or depth.
6) Data acquisition


Robot C-Frame Solution
The robot C-Frame friction stir spot welding FSSW solution can be integrated to any type of robot and is ideal for high volume applications, where the part has complex geometry.







Bench-Top Solution
Bench-top friction stir spot welding FSSW solution can be used for research and development, job-shop, or high volume applications. In a job shop environment, the system can be operated manually without fixture, if self-clamping system is used. In high-volume applications, multiple bench-top units can be integrated with a robot that can material handle parts under the unit.

 

Press Type Solution
The Pedestal FSSW solution can be used for research and develop, job-shop, or high volume applications. In a job shop environment, the system can be operated manually without fixture, if self-clamping system is used. In high-volume application, these systems can be integrated with a robot that places the part under the unit.

 

Custom, Fixed Friction Stir Welding (FSW) Systems
For applications not ideal for robotic solutions (high force), Friction Stir Link, Inc. can also provide customer engineered, fixed equipment solutions. Like the RoboStirTM, the system is all electrically actuated. These systems are multi-axis FSW systems that are engineered based on customer requirements, but typically are in gantry or C-frame configuration. These systems can be integrated with fixturing to suit customer need. Standard systems have the following capability;

Mini- Lini

Gantry Machine

1) Thrust force capability of 60 kN (12,000 lbs)
2) Traverse force capability of 20 kN (4,000 lbs)
3) Rotary power of 15 kW
4) Force control and position control capable
5) Force and torque monitoring
6) Segmented design to allow for any length and portability
7) Allen Bradley, ethernet, and Device Net based controls with Allen-Bradley Panelview for ease of support and training

All specifications can be modified to suit customer needs.

As with robotic system, FSL has multiple systems in production and brings that expertise to bear to allow for a robust, production capable FSW solution.