HEAVY-DUTY
How FSW works and the role of E6’s PCBN tools FSW is a solid-state joining process in which a rotating, non-consumable tool is plunged into the joint line between two plates and traversed along it. Frictional heating results in plasticisation, softening the steel around the tool without melting it. The tool’s shoulder and pin then forge the softened material together, forming a consolidated joint with a high-quality weld, refined microstructure, low defect rates and minimal porosity. Welding steel imposes extreme thermal
and mechanical demands on tooling, such as hot temperatures, high forces, severe wear, and stability requirements, making the FSW tool material and geometry critical determinants of weld quality, consistency and economic viability. E6’s PCBN tools are engineered
specifically to meet these challenges and withstand the high thermal and mechanical loads of steel FSW. PCBN combines extremely high heat hardness with excellent wear resistance and thermal stability, enabling tools to withstand the temperatures and loads encountered during welding of steels and high strength alloys, while maintaining dimensional stability and process control. By overcoming the heat, wear and stability limitations that typically constrain steel FSW, E6’s PCBN tools enable consistent weld formation, extended tool life and lower cost per metre of weld. This single pass technology is now
being used for thicker sections and tougher steel grades, opening up new applications that weren’t possible or practical with older, more conventional processes or earlier generation tools.
Welding a 25mm steel plate A recent successful collaboration between E6 and TWI has demonstrated the capability to weld a 25 mm thick steel plate. Using a sequential dual spindle approach, this marks a significant step in the industrialisation of steel FSW for heavy duty plate fabrication. Welding 25 mm steel typically
requires multiple passes with traditional welding processes, high heat input and extensive distortion management, with corresponding impacts on productivity and rework. To overcome these challenges, FSW is implemented from both the top and
bottom in carefully managed stages, using E6 PCBN tools on TWI’s POWERSTIR platform. This step-by-step approach allows operators to manage heat more effectively than welding both sides at once, helping prevent overheating and making it easier to achieve strong, reliable welds. The benefits of this technology for
heavy-duty fabricators include: • Reduced distortion and rework, particularly in thick sections, thanks to lower heat input and more uniform through-thickness heat distribution.
• More consistent weld quality, significantly reducing traditional fusion welding defects (e.g. lack of fusion, solidification, cracking).
• Potential to downgauge steel plate thickness, delivering lightweighting and cost savings while maintaining performance.
• Greater automation and repeatability, supporting industrial-scale deployment for heavy-plate welding in sectors such as shipbuilding, large structures and heavy vehicles.
Nickel steels for cryogenic and energy transition applications Nickel steels are essential for cryogenic storage and transport, especially for LNG and emerging low-temperature energy transportation. This is thanks to their combination of strength and toughness under cryogenic temperatures. Conventional welding of 9% nickel
steel is technically and commercially demanding. It relies on costly nickel- based filler metals and strict, carefully managed procedures to keep the steel tough at low temperatures. That all adds cost and complexity for building storage tanks and related infrastructures. FSW’s solid-state nature offers an
attractive route to reliably and cost- efficiently join 9% Ni steels while limiting heat input and microstructural degradation, consequently preserving cryogenic performance in the joint. E6’s PCBN tooling has been in-
field validated across a range of steel types, including challenging and dissimilar joints, providing the high-temperature hardness and wear resistance needed to weld 9% Ni successfully and reliably. As more trials are completed,
pairing FSW process control with E6’s trusted PCBN tools is elevating this
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technology as the most reliable choice for cryogenic storage and distribution in LNG and future low-carbon fuels.
What this means for welding engineers, production leaders and fabricators • FSW provides a high-integrity, repeatable alternative to conventional welding in heavy- duty and cryogenic steels.
• E6’s PCBN tooling is a key enabler, making steel FSW practical at an industrial scale by delivering the durability, dimensional stability and process control needed for consistent, economically viable production.
• The process supports improved quality, reduced rework, and greater automation, aligning with industry priorities around productivity, workforce challenges and digitalised fabrication.
• Adoption is accelerating as equipment, process understanding and tooling mature, giving stakeholders greater confidence to specify and deploy FSW in critical applications.
Looking ahead, E6 will continue to work with its wider ecosystem of industrial partners and end-users. This will be essential to expanding the process window and adoption of FSW of steel to support the heavy-duty sector’s productivity, reliability and decarbonisation goals. As equipment capability and process
understanding continue to advance, PCBN-enabled FSW is moving from specialised application to a viable scale production technology for heavy-duty steel. For fabricators facing increasing pressure on cost, quality and sustainability, the question is no longer whether FSW is feasible, but where it will deliver the greatest advantage.
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