Friction Stir Welding

Friction Stir Welding

Prototypes and Small Series – For the Automotive
Electronics, and Defense Industries

Friction Stir Welding (FSW) as an after treatment for aluminium and magnesium high-tech components like battery housings and inverters.

Friction Stir Welding – In-house at Formkon

Alu Kühlkörper von Formkon – komplexe Aluminium-Kühlkörperlösung mit integrierten Kanälen für effiziente Wärmeableitung in Leistungselektronik und Industrie.

At Formkon, we specialise in high-quality prototypes in aluminum and magnesium. We offer friction stir welding (FSW) in-house as a post-processing service for our cast and machined prototypes and small serie productions. This advanced method is especially ideal for high-tech components like battery housings and inverters, where a fully sealed joint between cooling channels and electronics is crucial.

Components with Friction Stir Welding

Friction stir welding is commonly used as a post-process for cast parts such as:

  • Battery housings and inverters for electric vehicles
  • Structural components where strength is critical
  • Components with integrated cooling channels

Industries That Benefit Most from FSW Post-Processing

We deliver fast, reliable, and precise results, tailored to your exact specifications.

Why In-House Friction Stir Welding?

By offering FSW in-house, we ensure:

  • Shorter lead times
  • Consistent results and high quality
  • Greater flexibility for design changes
Aluminium Die Casting - Inverter for E-mobility Prototype after post-processing by Friction Stir Welding

Why Choose Friction Stir Welding?

Compared to traditional welding methods, FSW offers key advantages:

  • Superior joint strength – Ideal for cooling channels and precision-cast parts
  • Dimensional accuracy and material integrity – Even for complex geometries
  • No melting involved – Avoids cracks, porosity, and distortion

How Friction Stir Welding Works

Friction stir welding joins two metal parts without melting. A rotating tool presses into the joint and moves along it, generating frictional heat and plasticizing the material. The softened metal is stirred and forged into a seamless, high-strength bond. Since the material remains solid throughout the process, you get stronger, cleaner welds with excellent mechanical properties and a high-quality finish.

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