Friction Stir Welding
PRODUCTS
Friction Stir Welding (FSW) – High-Strength, Defect-Free Solid-State Welding
Friction Stir Welding (FSW) is an advanced solid-state joining process that bonds materials without melting them.
At Cofan, our FSW technology uses a rotating tool to generate frictional heat, softening the material and creating a durable metallurgical bond with exceptional mechanical performance.
How Friction Stir Welding Works
- Secure Clamping – The two workpieces are firmly clamped to prevent movement.
- Frictional Heat Generation – A specially designed tool with a probe and shoulder rotates and penetrates the joint line.
- Material Softening – Heat is generated below the melting point, softening but not melting the base materials.
- Mechanical Mixing – As the tool travels along the joint, it stirs and blends the softened material from both sides.
- Solid-Phase Weld Formation – Upon cooling, the joint solidifies into a strong, defect-free weld.
Materials Suitable for FSW
- Aluminum alloys (0.3 mm to 75 mm thickness in a single pass)
- Magnesium, titanium, copper, nickel, and steel alloys
- Dissimilar materials – e.g., aluminum to steel
- Metal matrix composites (MMC) and select plastics
Advantages of Cofan FSW
- Defect-free welds – No hot cracking, porosity, or shrinkage distortion
- No consumables required – No filler wire, flux, or shielding gas for aluminum alloys
- Superior mechanical properties – High strength, toughness, and minimal residual stress
- Environmentally friendly – No fumes, spatter, or UV radiation
- Versatility – Suitable for joining “non-weldable” alloys (2xxx & 7xxx series aluminum)
- Automation ready – Easily integrated with CNC or robotic systems
Brazing Products
Product Information
- Dimension: L620mm x W330mm x T2.4mm
- Material: Al3003
- Power: 1000~1200W
Type A (Fitting on the bottom)
Type B (Fitting on the side)
Product Information
- Dimension: L420mm x W220mm x T2.4mm
- Material: Al3003
- Power: 600~800W
Type A (Fitting on the bottom)
Type B (Fitting on the side)
Product Information
- Dimension: L300mm x W150mm x T1.4mm
- Material: Al3003
- Power: 300~500W
Type A (Fitting on the bottom)
Type B (Fitting on the side)
Steps of FSW work
Rotating of stirring head
Stirring head insert into the workpieces
"Stir" begin
Welding
Work processes
1. Fasten the Products to be welded on the work table of the FSW machine
2. Adjust the Stirring head position to follow the welding process
3. Start the friction stir welding process
4. Examine the welded products and remove any excess and bur materials
5. Test the integrity of the welded products
6. Examine and packing
Samples
Processes
Friction Stir Welding
Applicable materials
Aluminum - Aluminum
Aluminum - Copper
Copper - Copper
Machines
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Equip. No.
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FSW-GC-3020
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|---|---|---|---|
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Welding Thickness
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1.5 - 25mm AL, Cu&Mg. alloy
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Working Table dimension(mm)
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3050 x 2000
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Stroke
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Positioning accuracy
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||
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Welding stroke & positioning accuracy (mm)
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X-axis
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3000
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0.08
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Y-axis
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2000
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0.06
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Z-axis
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500
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0.02
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C-axis
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n x 360º
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1′
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B-axis
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±5º
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Manually adjustable
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Main axis maxi. Speed (RPM)
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1500
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Brazing Reflow Oven
- Inlet of Brazing Reflow Oven: W500mm x H250mm
- Max.Temp. is around 630℃
- Facility area is around 30m x 3m
- Total equipment cost is around ￥500,000
Brazing Process Flow
1. Spray Solder Paste
2. Dry the Solder Paste
3. Heating Brazing
4. Cooling Process
Industry Applications
- Aerospace – Aircraft fuselage panels, wing structures
- Automotive & EV – Battery trays, lightweight body structures
- Shipbuilding & Marine – Hull plates, large structural assemblies
- Rail – Car body frames, lightweight panels
- Electronics – Heat sinks, structural frames
Limitations to Consider
- Exit hole at the end of the weld (can be designed out or managed with run-on/off tabs)
- High clamping forces required due to strong downforce during welding
- Gap control needed since no filler material is used
With state-of-the-art FSW equipment, custom tool design, and extensive material expertise, Cofan delivers precise, high-strength welds for demanding applications.
From prototype development to mass production, our engineering team provides solutions for complex joining challenges in multiple industries.