Building a Friction Stir Welding Tool 

We often make our own tools in-house rather than having them machined outside of the lab. This is the very beginning of a tool as it is cut on a lathe.   

After the lathe work is completed, the tool is placed in the CNC mill, where the bolt holes are added.

  

The CNC machine allows us to maintain tight tolerances on out tools, and it also makes for fine machine work. Here the machine is adding chamfers to the bolt holes.

These are the finished tools after heat treatment and polishing. The metal used for these tools is a special alloy chosen after extensive testing on our labs. 

Here the tool is being put to the test on 7075-T6 aluminum. This particular weld turned out perfect. 

CROSS-SECTION OF  THE FGM FSW TOOL TIP

 

 

 

FSW Tensile Test