In this special purpose machine, aluminium die-cast housings are joined to 3D-formed aluminium plates using friction stir welding (FSW). The components serve as cooler housings for power electronics in the battery charging management systems of electric vehicles.
The central challenge lies in the three-dimensional weld path across multiple component planes. Tight radii and inclined transition surfaces require precise kinematics and stable process control. For this purpose, the gantry system was expanded with a rotary-tilting table to create a fully capable 5-axis solution. Automatic alignment and clamping technology, robotic loading and process monitoring ensure reproducible FSW welding processes.