Friction Stir Welders

Model GS4-10,000 Vertical

A high quality multi axis machine specifically designed for vertical welding in development or production manufacturing where single plane straight line welding is required. The operator is presented with an HMI interface forparameter input and control. The machine has the ability to weldin both longitudinal (vertical) mode and circumferential mode. A fixture is required for specific diameters and includes facility for run on/run off strips.

Standard models availabe from FPE Ltd:
- GS4 10,000

FPE Ltd offer a full design and manufacture service for project specific friction stir welders.

Specifications
Software
Applications
Process
Industries

GS4 10,000 SPECIFICATION
WELDING SPINDLE
ROTATION (W-AXIS):	Clockwise / Anti-clockwise
TOOL HOLDER SIZE:	Size No: 50 (ANSI B5.18 - 1972)
SPINDLE SPEED:	0 - 3000 rpm
INCREMENTS:	1 rpm steps
MODE:	AC Servo
SPINDLE POWER:	22kW

WELDING HEAD
Z-AXIS:	3250mm
SPEED ACCURACY:	1mm / min
SPEED:	0.01 - 20 000mm/min
POSITIONAL ACCURACY:	0.02mm (better than)
X2-AXIS:	+/- 75mm
SPEED ACCURACY:	1mm / min
SPEED:	0.01 - 20 000mm/min
POSITIONAL ACCURACY:	0.02mm (better than)
MODE:	Hydraulic Servo

GS Control Software

The Siemens controller used is an NC control type 840D NCU 571.2, withinterface OP10. A Siemens servo drive motor type 1FT6 will be supplied for spindle rotation driven by Simodrive 611D speed variator

All software for control process is written to combine with the hardware configuration such that the system operates in complete closed loop control. The use of a unique hydraulic module allows the main force axis to be controlled in the same manner and thus making the finite control of all weld parameter achievable to incredibly high repeatable levels.

The use of this control technology gives advantages in the fine setting of parameters and limits with the added bonus that operator use is easy via special front end menus and password protection of the process

Software

Automotive

• Engine and chassis cradles
• Wheel rims
• Body panels

Railway Industry

• Rolling stock, underground carriages & trains
• Railway tankers and wagons
• Container bodies

Marine Industries

• Panels for decks, sides and bulkheads
• Aluminium extrusions
• Boat sections
• Hulls and superstructures
• Helicopter landing platforms

Land Transport Industry

• Truck bodies
• Fuel tankers
• Motorcycle and bicycle frames
• Buses and caravans
• Armour plated vehicles

Construction Industry

• Façade panels
• Window frames and air conditioners
• Pipe fabrication
• Aluminium bridges

Other industries

• Aerospace - military/civilian aircraft, rockets,
• Fuel tanks, aircraft parts
• Electrical - motor housings, busbars, electrical connectors
• Gas - Tanks and cylinders
• Chemical and Petrochemical - heat exchangers

Friction Stir Welding is a solid state joining process, in which a cylindrical shouldered tool with a profiled pin is inserted into the joint line between two pieces of material. Frictional heat is created between the wear resistant pin and the two work pieces, which are butted together and clamped onto a backing bar.

The heat causes the materials to soften, without reaching melting point, and allows the pin to traverse along the joint. As the tool moves along, the material is plasticised by the frictional heat at the front of the rotating pin and transported to the back. Here it consolidates and cools down to form a solid state weld.

FRICTION STIR WELDING PROCESS