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FSW

Services
Friction Stir Welding (FSW)

HAGE Mitarbeiter beim Bedienen einer Maschine mit der Aufschrift HAGE FSW
Friction Stir Welding (FSW) joins workpieces using a rotating special tool without the need for filler materials. The resulting frictional heat makes the material malleable without melting it, creating a homogeneous, high-strength joint as it cools. The process is particularly suitable for lightweight construction and is used in industries such as rail, aerospace, automotive, shipbuilding, and plant engineering.

Advantages
Friction
stir welding

Projects
  • High weld seam strength with low distortion — the low heat input largely preserves the material properties. Our systems control the process precisely, minimizing distortion even in XXL components.
  • HAGE WeldCheck — our software monitors every millimeter of the seam and enables continuous real-time monitoring.
  • HAGE Analyzer — the Analyzer software makes weld seams comparable and assessable at the click of a mouse.
  • Challenging material combinations — FSW enables mixed-material joints that would be difficult or impossible to realize with conventional welding.
  • High-speed series production — high-rigidity machine engineering supports high welding speeds and short takt times.
  • Custom clamping concepts — we develop tailored clamping solutions for every component geometry, including complex 3D contours.
  • Preliminary testing in our in-house FSW competence center — we test workpieces, optimize parameters and produce initial prototypes.
  • No shielding gases and no filler materials — FSW requires neither welding consumables nor shielding gases. This reduces operating costs and eliminates additional sources of error.
The

FSW Competence Center

We reduce your investment risk. In our in-house competence center, you can validate HAGE quality and the benefits of friction stir welding before making an investment decision.

  • Assessment of your workpiece requirements for FSW suitability
  • Geometry, process and parameter investigations
  • Development of custom clamping concepts
  • Production of initial prototypes and pre-series parts
  • Inspection and evaluation according to DIN EN ISO 25239 
  • Tool development for pins and shoulders

At the Core:
Two FSW Units

The competence center is equipped with two FSW units for simultaneous welding from opposite sides — a configuration that offers key advantages, particularly for symmetrical structural components.

Services:

Feasibility studies | Parameter optimization | Small-series production | Tool development

Projekte ansehen

Your Custom FSW Machine as a Complete Solution

From the initial workpiece analysis to a system commissioned anywhere in the world, HAGE supports you throughout the entire FSW process and ensures high quality and process reliability.
Request project
01

Non-binding Consultation

We analyze your requirements, assess your components for FSW suitability and identify potential opportunities.

02

Preliminary Testing in the HAGE Competence Center

In our in-house FSW competence center, we conduct feasibility studies and initial welding trials on your original workpieces. You receive sound prototype results before deciding on an investment in a production system.

03

Special Purpose Machine Engineering

Based on the results of the preliminary testing, we design and build your custom FSW system. Whether as a gantry system or a compact cell, we integrate advanced sensor technology and custom clamping concepts.

04

Process Development

We develop the specific welding strategies, program the NC sequences and adapt tools such as pins and shoulders to your application. With the help of the digital twin, we validate processes virtually and reduce real ramp-up times.

05

Process Optimization

We support the ramp-up of your production and continuously optimize the parameters to reduce takt times and further stabilize weld quality. Our goal is maximum cost-effectiveness and stability in your ongoing series production.

06

Continuous Process Monitoring

Real-time monitoring and analysis ensure consistently high weld quality.

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