TECHNOLOGY IN FOCUS


FRICTION STIR WELDING (FSW) TECHNOLOGY


F


riction 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.


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 aluminium 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.


The 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.


Improvement of joint strength Unlike electron beam welds, that have


coarse grains, the 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.


EV applications for FSW In the automotive industry, not only


the shift from engines to motors as power sources but also the introduction of


42 / WELDING WORLD MAGAZINE - ISSUE 04 - AUGUST 2025


new technologies such as connectivity with the internet, autonomous driving, and electrification have created new demands for component manufacturing. In order to meet this demand, the


construction of high-precision and flexible production systems is crucial. Mazak contributes to the high-precision machining of automotive parts with a comprehensive range of machining technologies, offering turnkey solutions that support the introduction and operation of automation systems. Furthermore, the company provides solutions that address cost reduction per part and minimise the impact on the global environment. For module components that make


up motors, batteries, and other systems, welding technologies are required to integrate the parts together. Mazak has developed the FSW-460V, which is equipped with FSW technology, that softens materials through friction heat to enable fast and stable welding. The FSW-460V features a high-speed,


high-rigidity FSW spindle for rapid joining. Stable joining accuracy is maintained by a control function that keeps the tool thrust force constant with high-quality corner joints and zero degree tool tilt. It is also equipped with an automatic tool holder replacement function so is capable of continuous bonding for long periods of time improving productivity and efficiency. Based on a double column vertical


machining centre offering combined high accuracy machining and welding the


Mazak FSW-460V has an integrated No.50 taper high strength spindle. Thanks to the large 2,240 by 1,250 mm worktable a wide range of applications from large workpieces, thin worksheets and multi- surface machining can be performed. OEMs can shorten lead times and reduce work-in-process inventory by using a single machine to complete all processes from joining to cutting of medium to large parts. This technology can be used to


manufacture electric vehicle (EV) related parts such as inverter cases, battery cases and motor cases. Compact and lightweight components can be produced without bolted connections. It helps improved durability due assembly bonding with no need for sealing materials.


www.mazak.com


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


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