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Friction Stir Welding Machines

Friction Stir Welding Machines
Friction Stir Welding Machines Friction Stir Welding Machines Friction Stir Welding Machines Friction Stir Welding Machines Friction Stir Welding Machines Friction Stir Welding Machines

Model GS4-10,000 Vertical


A high quality multi axis CNC Friction Stir Welding and Milling 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 for parameter input and control. The machine has the ability to weld in both longitudinal (vertical) mode and circumferential mode and has the facility for preparation edge milling. A fixture is required for specific diameters and it includes facility for run on/run off strips and milling mode.


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Gatwick Model CNC 15FSW


A high quality 4 axis CNC machine specifically designed for Friction Stir Welding small aluminium components or sheet or for demonstration in Universities or Institutions.  Manual load and unload of sheet or components into the clamping area as standard.  2mm depth aluminium is the limit of this machine


Standard models available from Gatwick:

- GS4 10,000


-CNC 15FSW


Gatwick offer a full design and manufacture service for project specific friction stir welding machines.


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  • 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
Gatwick CNC 15FSW              
WELDING SPINDLE 
ROTATION (W-AXIS): Clockwise / Anti-clockwise
TOOL HOLDER SIZE: Size No: 50 (ANSI B5.18 - 1972)
SPINDLE SPEED: 0 - 8000 rpm
INCREMENTS: 1 rpm steps
MODE: AC Servo
SPINDLE POWER: 1.5kW

 
WELDING HEAD 
Z-AXIS: 800mm
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:
 Electric

GS Control Software

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

All software for the 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

  • Fa├žade 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

FRICTION STIR WELDING PROCESS

FRICTION STIR WELDING PROCESS

example weld

Stir Weld

FPE and Gatwick Fusions range of Friction Stir Welders are suitable for the following industries:

  • AEROSPACE
  • AUTOMOTIVE
  • ELECTRICAL
  • INDUSTRIAL