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Aluminum Wire for Friction Stir Welding (FSW) Tools

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Product Description

Specialized high-strength aluminum materials, often based on 2XXX or 7XXX series (e.g., 2219, 7075), used not as filler metal, but as the raw material for manufacturing Friction Stir Welding (FSW) tools (pins and shoulders). These materials are chosen for their exceptional high-temperature hardness, wear resistance, and creep strength at the elevated temperatures (∼400∘C) generated during the FSW process. The rods/billets are manufactured with ultra-tight dimensional and chemical control to ensure the integrity and longevity of the non-consumable FSW tool.

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20+ Years Experience

Over two decades of aluminum alloy wire production expertise

International Certifications

DB, CE, ABS, DNV, CCS and other authoritative certifications

200MT Monthly Capacity

Large-scale production with consistent quality

Global Export

Exporting to over 30 countries worldwide

Introduction

Friction Stir Welding (FSW) is a solid-state joining process that creates high-integrity welds without melting the material, relying instead on a non-consumable, rotating tool to generate friction and plasticize the metal. We supply the critical high-performance aluminum tooling stock required for FSW tool manufacturers. By controlling the chemistry and grain structure of the tooling material, we ensure maximum tool life, minimizing the costly tool wear that dictates the operational efficiency of major FSW users in aerospace and rail industries.

Specification

Material RoleTooling Stock (Non-Consumable, High Hardness)
Alloy FocusHigh-Strength Aluminum Alloys (2XXX or 7XXX for tool body)
Key PropertyHigh Hot Hardness, Wear Resistance, High Creep Strength
Typical FormRods or Billets with T6/T7 Temper
Operating TemperatureTooling must withstand up to 450∘C in the weld zone

Applications and Solutions

  • FSW Tool Manufacturing: Providing the high-strength aluminum rods used to machine the rotating shoulder and pin elements of the FSW tool.

  • Aerospace Structures: Tools used for FSW of aircraft fuselages, fuel tanks (Al-Li), and wings, where minimal distortion and high fatigue resistance are critical.

  • Rail and Automotive: FSW of large aluminum extrusions for high-speed rail cars and specialized automotive battery trays.

  • Dissimilar Alloy Welding: FSW tools optimized for joining previously unweldable combinations, such as Al to Mg or Al to Cu.

FAQ

  • Q: Why is a specialized aluminum tool needed for FSW of aluminum?A: While high-performance steel or even ceramics are used for some FSW applications, specialized high-strength aluminum tools are often preferred for welding soft aluminum alloys because they offer the right balance of hardness and matching thermal properties to the base metal.
  • Q: What type of heat treatment is used on FSW tool stock?A: FSW tool materials typically receive a T6 or T7 temper (Solution Heat Treatment and Artificial Aging) to maximize the strength and hardness required to withstand the high shear forces.
  • Q: Is this wire a consumable in FSW?A: No. This material is the tooling stock used to manufacture the non-consumable FSW tool itself. FSW is a solid-state process and does not typically use filler metal.

Advantages and Core Features

  • Maximized Tool Life: Superior thermal stability and wear resistance of the tooling material minimize material transfer and tool degradation.

  • Consistent Weld Quality: Tools maintain their precise geometry longer, ensuring consistent material mixing and flow for a defect-free FSW joint.

  • Reduced Downtime: Longer tool life translates directly to reduced operational downtime and lower consumable costs for the end-user.

  • Precise Geometry Machining: Supplied with tight dimensional tolerance and uniform grain structure for high-precision CNC machining of the tool profile.

Material Selection Guide

For FSW tool material, select high-strength alloys with excellent thermal stability. 7075 is a common choice for its strength, while certain 2XXX series (like 2219) are used for their high-temperature stability. The choice depends entirely on the base metal being welded and the desired tool life. Always specify the required temper (T6 or T7).

About Us

Coming From China, Marketing To The World.

Hangzhou Kunli welding materials Co., Ltd. is China Aluminum Wire for Friction Stir Welding (FSW) Tools Manufacturers and Wholesale Aluminum Wire for Friction Stir Welding (FSW) Tools OEM/ODM Suppliers. We are located in the industrial zone of Puyang Town, Xiaoshan District, Hangzhou, Zhejiang Province. It is a high-technology enterprise specializing in the research, development and manufacturing of high-performance. The company has more than 20 years of aluminum alloy wire production experience, with international advanced manufacturing equipment, complete testing equipment,stable production process and strict quality control system.
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