Known as a ‘green’ joining technology for non-ferrous metals such as aluminium, friction stir welding (FSW) has established itself in a number of industries. In future, manufacturing companies using Heller machines will no longer need any additional hardware for this technology. Instead, they will be able to perform this process in a single set-up on their four-axis or five-axis machining centres.

FSW is a good choice when it comes to producing high-quality, cavity-free and tight welded joints with excellent fatigue properties. Accordingly, this process is often applied in the manufacture of reservoirs, tanks and containers, as well as in shipbuilding and aerospace engineering. In addition, FSW is increasingly establishing itself in the electrical industry and in automotive engineering with the growth of e-mobility, for the welding of battery housings.

Due to the comparatively low heat input, a very fine-grained structure results without cracks or pores in the material, while distortion in the component is minimal. The welded seam therefore meets the highest standards in terms of tightness and crash behaviour.

FSW also offers a number of key advantages with regard to the environment and health.Compared with conventional welding methods, there are no dangerous light flashes or hazardous fumes, for example.

The welding process becomes a particularly interesting technology with the successful integration into Heller machine tools. It allows users to eliminate an additional work step and only requires inexpensive tools, activation of the Heller technology cycle and the ‘adaptive control function’ in the Sinumerik 840D sl control.The machine operator can easily program the welding path at the CNC control panel using G code, while the transfer of CADCAM data is also possible without any problems.
For further information www.heller.biz