Views: 35 Author: Site Editor Publish Time: 2026-07-09 Origin: Site
Traditional fusion welding often brings unavoidable defects for lightweight metal parts, including porosity, cracks, severe deformation, weakened joint strength and unstable electrical conductivity. For manufacturers in EV, aerospace and rail transit pursuing high reliability and consistent production, friction stir welding (FSW) has become the optimal joining technology.
As a professional precision metal processing manufacturer, we deliver mature FSW welding services covering prototype trial, small-batch testing and mass production. Our solid-state welding solutions resolve the core pain points of aluminum, copper and dissimilar metal assembly for global industrial clients.
Friction stir welding is a revolutionary solid-state joining process without melting base materials. A rotating stirring tool plunges into the workpiece and travels along the welding path. Frictional heat generated by tool rotation softens the metal to a plastic state, and continuous stirring & forging action forms a dense, seamless metallurgical bond between two workpieces.
The whole process requires no welding wire, shielding gas or flux, eliminating arc flash, smoke and spatter completely. Compliant with ISO 25239 industrial standards, FSW delivers stable, repeatable welding quality for high-precision structural components.
No porosity, cracks or oxidation in weld seams. Joint mechanical performance retains over 90% of base metal strength, with outstanding fatigue resistance and airtightness. Ideal for liquid cooling plates, battery trays and sealed housings with strict leak-proof requirements.
Low heat input sharply reduces residual stress and thermal distortion. Post-weld straightening and polishing procedures are greatly cut down, lowering scrap rate and overall production cost.
Perfect for 5xxx/6xxx/7xxx series aluminum, magnesium, copper alloys; capable of joining dissimilar metals like aluminum-copper that cannot be reliably welded via fusion processes. It unlocks lightweight design and high-conductivity electrical assembly solutions.
No consumables such as filler wires or protective gas; energy consumption is 30%–50% lower than arc welding. Zero toxic fumes and radiation simplify workshop environmental management and meet global green manufacturing standards.
Uniform, impurity-free welds maintain consistent conductivity and heat transfer, a critical merit for new energy power components like busbars and cooling structures.
EV battery trays, water cooling plates, battery housings, aluminum-copper busbars, inverter shells and lightweight chassis parts. FSW guarantees long-term airtightness and structural safety for power battery systems.
High-strength aluminum fuselage frames, heat dissipation structures, sealed bearing components, and lightweight load-bearing parts requiring high fatigue resistance.
Train carriage aluminum panels, cooling modules, vehicle body lightweight extruded profiles and sealed pipeline structures.
Heat sink enclosures, electronic control cabinets, communication equipment housings and custom sealed aluminum structural parts.
We provide one-stop friction stir welding services tailored to your project specifications:
Custom Process Development
Our engineering team designs dedicated stirring tools, welding trajectories and parameter sets according to your material thickness, structure and performance standards, including flat butt welding, lap welding, corner welding and static shoulder FSW for ultra-smooth surface finish.
Complete Quality Inspection System
Full quality control covering tensile testing, fatigue testing, metallographic analysis and non-destructive flaw detection (X-ray, penetration test). All welding records are traceable for mass production.
Full-Cycle Technical Support
Free drawing evaluation & sample trial production; flexible small-batch pilot run and large-scale automated mass production; technical iteration support for complex thin-walled, thick-plate and special-shaped workpieces.
Integrated Machining Service
We combine FSW with CNC machining, surface treatment (anodizing, passivation, laser marking) to deliver finished ready-to-assemble parts, saving your multi-supplier coordination cost.
Comparison Item | Friction Stir Welding | MIG/TIG Fusion Welding |
|---|---|---|
Weld Defects | Zero porosity & cracks | High risk of pores, cracks & oxidation |
Workpiece Deformation | Ultra-low | Severe thermal deformation |
Joint Strength | Close to base material | Obvious strength loss in heat-affected zone |
Consumables | No wire/gas required | Welding wire, shielding gas needed |
Dissimilar Metal Joining | Mature & reliable | Hard to achieve stable bonding |
Post-Weld Processing | Minimal correction needed | Heavy polishing & straightening work |
If you are facing welding difficulties with aluminum, copper or dissimilar metal assemblies, send us your drawings, material specs and performance requirements. Our technical engineers will provide free process assessment, sample quotation and customized friction stir welding solutions to boost your product reliability and production efficiency.
We have very strict quality control flow to follow, We are quite confident to meet your requirements. Contact us today to discuss your high-precision metal joining project.
Please send us your detail inquiry:
- 2D or 3D drawing or Sample
- quantity
- surface finish requirement
...
We will provide quotes within 12 hours, thanks again.
Anna Zhong
JV Precision Manufacturing Co.,Ltd.
DongGuan JIECHEN Precision Hardware Manufacturing Co.,Ltd.
TEL: +86 153 3836 0970 (whatsapp, wechat)
E-mail: anna.zhong@jvprecisionmfg.com
Website: www.jvprecisionmfg.com
