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FSW System for Rocket Tank Bulkheads

For the space industry, HAGE realized a custom, approximately 50 m long FSW system for machining and friction stir welding bulkheads for rocket tanks.
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The hemispherical aluminium workpieces, with diameters of up to 6 m, are machined and then friction stir welded to tank cylinders or domes.

The system concept combines milling, the FSW process, 3D geometry scanning, ultrasonic testing and real-time process monitoring. Two A-gantries, RPT technology, separate pin and shoulder axes, and redundant measuring systems enable precise control of the relevant process variables for demanding aluminium structural components.

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Technical Data

  • System length: approx. 50 m
  • 2 A-gantries with 80 kN and 9 axes
  • Milling and FSW machining head with RPT function
  • Separate pin and shoulder axis
  • Path-force control for pin and shoulder axis
  • Tool change system with magazine for milling tools

Highlights

  • Integrated milling and FSW machining for space components
  • Machining of large-format aluminium dome segments
  • RPT technology for demanding welding processes
  • Process monitoring with HAGE WeldCheck
  • Combination of geometry scan, ultrasonic testing and real-time data analysis