Friction Stir Welding of cooling channels for Die Casting Inverters

At Formkon, we are pioneers in manufacturing prototypes for e-mobility and offer friction stir welding in-house to optimize the production of cooling channels for pressure die-casting inverter components. This strategic decision enables us to achieve faster market introduction and offer tailored solutions for prototype projects in e-mobility.

Why Choose Friction Stir Welding at Formkon?
As experts in prototypes for e-mobility, we focus on utilizing innovative manufacturing technologies like friction stir welding. With our in-house production of friction stir welded parts, we can quickly respond to customer requirements and implement projects in a short time, leading to accelerated market introduction of pressure die-casting inverter projects.

More About Friction Stir Welding
Friction stir welding is an innovative joining technique distinguished by its diverse applications and outstanding properties. In this process, workpieces are joined together without melting by guiding a rotating pin under pressure across the workpieces to be joined. The plastic deformation of the material creates a solid and homogeneous connection characterized by high strength, precision, and minimal distortion.

This technique is particularly well-suited for manufacturing components in e-mobility, such as cooling channels for inverter components. Friction stir welding allows for the production of complex geometries that meet the specific requirements of e-mobility.

The roots of friction stir welding trace back to its invention by The Welding Institute (TWI) in 1991, with researchers Wayne Thomas and Graham Threadgill pioneering its development. Initially conceived as a method for joining aluminum alloys in the aerospace industry, FSW has since evolved into a versatile joining process with applications across various sectors, including automotive, marine, and, notably, e-mobility.

This solid-state nature of FSW imparts several advantages. First and foremost, it eliminates the formation of solidification defects such as porosity and hot cracks commonly encountered in fusion welding processes. Additionally, since there is no liquid phase involved, the risk of solidification shrinkage and distortion is significantly reduced, leading to superior dimensional stability and weld quality.

Friction Stir Welding