Friction Stir Welding (FSW) Technology
Friction Stir Welding (FSW) is a technology that uses frictional heat generated by a rotating tool to join two metal plates together. Productivity can be greatly improved by applying FSW technology to the manufacture of EV-related components such as inverter cases, battery cases and motor cases, as well as the joining of cooling parts for semiconductor equipment.
FSW benefits
Joints with less deformation and distortion
Since materials other than the material are not used and no material is melted, the joint can be strong with little deformation or distortion.
Capable of joining different materials
It is possible to join not only the same materials, but also different materials such as aluminum and steel.
Safe and comfortable working environment
The FSW technology allows for use in a safe environment with no emissions of gases, smoke, sputter, plasma or X-rays.
![FSW-460V [High-speed FSW] Friction Stir Welding Example of battery case welding [JIMTOF2022 exhibition machine] FSW-460V](/content/mazak/local-sites/jp/en/products/fsw/_jcr_content/root/container/container_539716508/container_copy_copy/container/container/container_1929369336/image.coreimg.100.1920.jpeg/1717661856387/lgollfyo-ei.jpeg)
FSW process
Unlike conventional welding, which melts the materials and joins them together, FSW stirs and joins materials softened by frictional heat at a temperature below the melting point. There are two methods of material joining: butt joining and lap joining.
- 1: Joint temperature below melting point
- 2: Junction direction
- 3: Tool thrust force
- 4: Direction of tool rotation
- 5: Shoulder
- 6: Probe
- 7: Axis direction plastic flow
- 8: Rotation direction plastic flow
Examples of proposals for the automotive industry
Mazak FSW benefits
Mazak’s unique FSW technology ensures stable joint quality.
Joint depth 3 mm
| Material | spindle speed |
| A6063 | 2500 mm/min |
| A5052 | 2000 mm/min |
| ADC12 | 1500 mm/min |
| C1020 | 300 mm/min |
Improvement of joint strength
Unlike electron beam welds, which have coarse grains, FSW joints have finer grains than the base material, improving joint strength. Joining strength is improved not only when joining the same materials, but also when joining different materials.
Benefits of using FSW for electronic module components
This technology can be used to manufacture electric vehicle (EV) related parts such as inverter cases, battery cases, and motor cases.
- Compact and lightweight with no need for bolted connections
- Improved durability due to all-assembly bonding with no need for sealing materials
Examples of proposals for the semiconductor industry
Use in semiconductor equipment components
Applied to the joining of backing plates and cooling plates used in semiconductor equipment, the process from joining parts to cutting can be completed in a single machine. As a result, lead time can be shortened and work-in-process inventory can be reduced.
Process integration for cooling panel manufacturing
- Machined base
- Friction stir welding of the lid and base
- Friction stir welding of the lid and base
- Surface finishing by cutting
Cooling panel machining video
Application Examples
Compatible models
Combined FSW technology with double column and vertical machining centers
Shorten lead time and reduce work-in-process inventory by using a single machine to complete all processes from joining to cutting of medium to large parts
High speed and high quality FSW processing machine
Supports high-speed, high-quality joining and long-time continuous joining, contributing to mass production and improved production efficiency
