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FSW System for Large-Format Floor Panels in Railcar Manufacturing

For the production of large-format floor panels in modern railcar manufacturing, HAGE realized a high-performance FSW system for aluminium extruded profiles and plate structures.
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The current workpiece dimension is approx. 5,000 x 2,300 x 300 mm; the system concept can be expanded for profile lengths up to 17,000 mm.

An upper and an identical lower FSW spindle enable synchronized double-sided welding. This means components are welded simultaneously from above and below, reducing distortion, improving flatness and shortening takt times. Automatically adjustable special clamping fixtures ensure high flexibility for different assemblies and variants.

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Technical Data

  • Gantry system with 70 kN and 6 axes
  • Lower spindle unit with 70 kN and 2 axes
  • Current workpiece dimension: approx. 5,000 x 2,300 x 300 mm
  • Expandable to profile lengths up to 17,000 mm
  • Maximum weld seam length: 20 m
  • Variable material thicknesses: 4.2–30 mm
  • Maximum welding force: 70 kN

Highlights

  • Double-sided FSW for large-format aluminium floor panels
  • Reduced weld distortion and improved component flatness
  • High flexibility through adjustable clamping technology
  • Machining of very long profiles and plate structures
  • Automatic weld gap control for process assurance
  • Automatically adjustable special clamping fixtures